Thermoset composition, method, and article

ABSTRACT

A curable composition includes a functionalized poly(arylene ether), an alkenyl aromatic monomer, an acryloyl monomer, and a polymeric additive selected from polystyrene, poly(styrene-maleic anhydride), poly(styrene-methyl methacrylate), polybutene, poly(ethylene-butylene), poly(vinyl ether), poly(vinyl acetate), and combinations thereof. Curable compositions comprising polybutene having a number average molecular weight of greater than or equal to 300 atomic mass units form sol-gels having sol-gel transition temperatures of greater than about 60° C. These sol-gel compositions also exhibit lower tack at ambient temperature.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.10/119,406, filed Apr. 9, 2002, which is incorporated by referenceherein in its entirety.

BACKGROUND

Thermoset molding compositions known in the art are generallythermosetting resins containing inorganic fillers and/or fibers. Uponheating, thermoset monomers initially exhibit viscosities low enough toallow for melt processing and molding of an article from the filledmonomer composition. Upon further heating, the thermosetting monomersreact and cure to form hard resins with high stiffness. Some thermosetmolding compositions derived from poly(arylene ether) and alkenylaromatic monomers exhibit a substantial drop in viscosity when heatedabove approximately 60° C. At molding temperatures, often well above 60°C., the drop in viscosity may contribute to poor glass carry andnon-uniform glass bundle distribution of molded thermoset compositionscontaining glass or other fillers.

One industrial use of thermoset compositions is the molding ofautomotive body panels. These panels preferably exhibit high dimensionalstability and a smooth as-molded surface. It is also preferred that thedimensions of the molded parts conform closely to those of the moldsused to prepare them.

Thermoset compositions based on unsaturated polyester resins and styreneare known to exhibit reduced shrinkage and improved surface propertieswhen they incorporate a so-called low-profile additive, such as apolymethacrylate copolymer. See, for example, V. A. Pattison et al. J.Appl. Poly. Sci, volume 18, pages 2763–2771 (1974). Although knownlow-profile additives improve the performance of the polyesterthermosets, there is a need for compositions exhibiting furtherimprovements, particularly in surface characteristics.

U.S. Pat. No. 6,352,782 to Yeager et al. describes thermosetcompositions comprising poly(arylene ether) resins that have been cappedwith ethylenically unsaturated groups. These compositions exhibitdesirable properties including high glass transition temperatures andlow coefficients of thermal expansion. However, low-profile additivesknown for polyester thermosets are ineffective in the poly(aryleneether)-containing compositions.

Some thermoset compositions exhibit tack in their curable form. Curableresins exhibiting tack makes them difficult to handle, adhering to itemssuch as equipment, clothes, containers, etc. Tackiness may result in auniform mass of resin in a storage container rather than individualpieces or pellets in a free-flowing form. Special packaging methods mustbe used to avoid such problems in the handling and transfer of tackyresins.

There remains a need for thermoset compositions exhibiting reducedshrinkage on molding and improved surface characteristics. There alsoremains a need for curable thermoset compositions having reduced tack.Finally, there remains a need to maintain sufficient viscosity ofthermoset compositions during molding at elevated temperatures in orderto provide good glass carry and uniform glass bundle distribution duringmolding.

BRIEF SUMMARY

The above-described and other drawbacks are alleviated by a curablecomposition, comprising: a functionalized poly(arylene ether); analkenyl aromatic monomer; an acryloyl monomer; and a polymeric additiveselected from the group consisting of a polystyrene, apoly(styrene-maleic anhydride), a poly(styrene-methyl methacrylate), apolybutene, a poly(ethylene-butylene), a poly(vinyl ether), a poly(vinylalkanoate) wherein the alkanoate group has at least three carbons, andcombinations comprising at least one of the foregoing polymericadditives.

Another embodiment is a curable composition, comprising: afunctionalized poly(arylene ether); an alkenyl aromatic monomer; anacryloyl monomer; and a polybutene, wherein the polybutene has a numberaverage molecular weight of greater than or equal to about 300 atomicmass units.

Another embodiment is a curable composition, comprising: afunctionalized poly(arylene ether); an alkenyl aromatic monomer; anacryloyl monomer; and a polybutene, wherein the polybutene has a numberaverage molecular weight of greater than or equal to about 300 atomicmass units and wherein the curable composition is a sol-gel having asol-gel transition temperature of greater than about 60° C.

Other embodiments, including a method of preparing a curablecomposition, a cured composition comprising the reaction product of thecurable composition, and articles comprising the cured composition, aredescribed below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a graph exhibiting viscosity at a mixing temperature (60°C.) for thermoset molding compositions comprising polybutenes of varyingmolecular weights and viscosity at 25° C. for the thermoset moldingcompositions after cooling;

FIG. 2 depicts a graph exhibiting sol-gel transition temperatures forthermoset molding compositions comprising polybutenes of varyingmolecular weights;

FIG. 3 is a confocal microscopy image of the 3-D nature of a sol-gel.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

One embodiment is a curable composition, comprising: functionalizedpoly(arylene ether); an alkenyl aromatic monomer; an acryloyl monomer;and a polymeric additive selected from the group consisting of apolystyrene, a poly(styrene-maleic anhydride), a poly(styrene-methylmethacrylate), a polybutene, a poly(ethylene-butylene), a poly(vinylether), a poly(vinyl alkanoate) wherein the alkanoate group has at leastthree carbons, and combinations comprising at least one of the foregoingpolymeric additives.

In another embodiment a curable composition comprises a functionalizedpoly(arylene ether); an alkenyl aromatic monomer; an acryloyl monomer;and a polybutene, wherein the polybutene has a number average molecularweight of greater than or equal to about 300 atomic mass units.Preferably the curable composition comprises a sol-gel having a sol-geltransition temperature of greater than about 60° C., more preferablygreater than or equal to about 75° C., and even more preferably greaterthan or equal to about 90° C. Compared to compositions without apolybutene having a number average molecular weight of greater than orequal to about 300 atomic mass units, these curable compositions exhibita significantly smaller decrease in viscosity upon heating to moldingtemperatures thereby facilitating good glass carry and good glass bundledistribution. During an exemplary molding process, the curablecomposition containing filler is added to a heated mold. The curablecomposition is warmed to the mold temperature, turning from a waxy solidto a flowing resin when the sol-gel transition temperature has beenachieved and/or surpassed. It is believed that the sol-gel compositionsdescribed herein exhibit greater glass carry and glass bundledistribution because the composition in the mold remains in a solidifiedform longer, thereby preventing the filler from settling out in themold.

“Sol-gel” as defined herein is as a multiphase system that isnonflowing. The multiphase system can be described as a bicontinuousstructure or an interconnected network. One phase of the bicontinuousstructure may be described as the “scaffolding” and the other phase isinterwoven within the scaffolding. The sol-gel transition temperature isthe temperature below which the system phases separate and form aninterconnected network, and above which the system phases becomemiscible and the gel dissolves into a flowing liquid. Sol-gel transitiontemperatures as high as 105° C. may be achieved.

The composition comprises a functionalized poly(arylene ether), whichmay be a capped poly(arylene ether) or a ring-functionalizedpoly(arylene ether), each of which is defined below.

The functionalized poly(arylene ether) may be a capped poly(aryleneether). A capped poly(arylene ether) is defined herein as a poly(aryleneether) in which at least 50%, preferably at least 75%, more preferablyat least 90%, yet more preferably at least 95%, even more preferably atleast 99%, of the free hydroxyl groups present in the correspondinguncapped poly(arylene ether) have been functionalized by reaction with acapping agent.

The capped poly(arylene ether) may be represented by the structureQ(J-K)ywherein Q is the residuum of a monohydric, dihydric, or polyhydricphenol, preferably the residuum of a monohydric or dihydric phenol, morepreferably the residuum of a monohydric phenol; y is 1 to 100; Jcomprises repeating structural units having the formula

wherein m is 1 to about 200, preferably 2 to about 200, and R¹–R⁴ areeach independently hydrogen, halogen, primary or secondary C₁–C₁₂ alkyl,C₂–C₁₂ alkenyl, C₂–C₁₂ alkynyl, C₁–C₁₂ aminoalkyl, C₁–C₁₂ hydroxyalkyl,phenyl, C₁–C₁₂ haloalkyl, C₁–C₁₂ hydrocarbonoxy, C₂–C₁₂halohydrocarbonoxy wherein at least two carbon atoms separate thehalogen and oxygen atoms, or the like; and K is a capping group producedby reaction of a phenolic hydroxyl group on the poly(arylene ether) witha capping reagent. The resulting capping group may be

or the like, wherein R⁵ is C₁–C₁₂ alkyl, or the like; R⁶–R⁸ are eachindependently hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₆–C₁₈ aryl,C₇–C₁₈ alkyl-substituted aryl, C₇–C₁₈ aryl-substituted alkyl, C₂–C₁₂alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl, C₇–C₁₈ alkyl-substitutedaryloxycarbonyl, C₇–C₁₈ aryl-substituted alkoxycarbonyl, nitrile,formyl, carboxylate, imidate, thiocarboxylate, or the like; R⁹–R¹³ areeach independently hydrogen, halogen, C₁–C₁₂ alkyl, hydroxy, amino, orthe like; and wherein Y is a divalent group such as

or the like, wherein R¹⁴ and R¹⁵ are each independently hydrogen, C₁–C₁₂alkyl, or the like.

In one embodiment, Q is the residuum of a phenol, includingpolyfunctional phenols, and includes radicals of the structure

wherein R¹–R⁴ are each independently hydrogen, halogen, primary orsecondary C₁–C₁₂ alkyl, C₁–C₁₂ alkenyl, C₁–C₁₂ alkynyl, C₁–C₁₂aminoalkyl, C₁–C₁₂ hydroxyalkyl, phenyl, C₁–C₁₂ haloalkyl, C₁–C₁₂aminoalkyl, C₁–C₁₂ hydrocarbonoxy, C₁–C₁₂ halohydrocarbonoxy wherein atleast two carbon atoms separate the halogen and oxygen atoms, or thelike; X may be hydrogen, C₁–C₁₂ alkyl, C₆–C₁₈ aryl, C₇–C₁₈alkyl-substituted aryl, C₇–C₁₈ aryl-substituted alkyl, or any of theforegoing hydrocarbon groups containing at least one substituent such ascarboxylic acid, aldehyde, alcohol, amino radicals, or the like; X alsomay be sulfur, sulfonyl, sulfuryl, oxygen, or other such bridging grouphaving a valence of 2 or greater to result in various bis- or higherpolyphenols; y and n are each independently 1 to about 100, preferably 1to 3, and more preferably about 1 to 2; in a preferred embodiment, y=n.Q may also be the residuum of a diphenol, such as2,2′,6,6′-tetramethyl-4,4′-diphenol.

In one embodiment, the capped poly(arylene ether) is produced by cappinga poly(arylene ether) consisting essentially of the polymerizationproduct of at least one monohydric phenol having the structure

wherein R¹–R⁴ are each independently hydrogen, halogen, primary orsecondary C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₂–C₁₂ alkynyl, C₁–C₁₂aminoalkyl, C₁–C₁₂ hydroxyalkyl, phenyl, C₁–C₁₂ haloalkyl, C₁–C₁₂hydrocarbonoxy, C₂–C₁₂ halohydrocarbonoxy wherein at least two carbonatoms separate the halogen and oxygen atoms, or the like. Suitablemonohydric phenols include those described in U.S. Pat. No. 3,306,875 toHay, and highly preferred monohydric phenols include 2,6-dimethylphenoland 2,3,6-trimethylphenol. The poly(arylene ether) may be a copolymer ofat least two monohydric phenols, such as 2,6-dimethylphenol and2,3,6-trimethylphenol.

In a preferred embodiment, the capped poly(arylene ether) comprises atleast one capping group having the structure

wherein R⁶–R⁸ are each independently hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂alkenyl, C₆–C₁₈ aryl, C₇–C₁₈ alkyl-substituted aryl, C₇–C₁₈aryl-substituted alkyl, C₂–C₁₂ alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl,C₇–C₁₈ alkyl-substituted aryloxycarbonyl, C₇–C₁₈ aryl-substitutedalkoxycarbonyl, nitrile, formyl, carboxylate, imidate, thiocarboxylate,or the like. Highly preferred capping groups include acrylate(R⁶=R⁷=R⁸=hydrogen) and methacrylate (R⁶=methyl, R⁷=R⁸=hydrogen).

In another preferred embodiment, the capped poly(arylene ether)comprises at least one capping group having the structure

wherein R⁵ is C₁–C₁₂ alkyl, preferably C₁–C₆ alkyl, more preferablymethyl, ethyl, or isopropyl. The present inventors have surprisinglyfound that the advantageous properties of their invention can beachieved even when the capped poly(arylene ether) lacks a polymerizablefunction such as a carbon-carbon double bond.

In yet another preferred embodiment, the capped poly(arylene ether)comprises at least one capping group having the structure

wherein R⁹–R¹³ are each independently hydrogen, halogen, C₁–C₁₂ alkyl,hydroxy, amino, or the like. Preferred capping groups of this typeinclude salicylate (R⁹=hydroxy, R¹⁰–R¹³=hydrogen).

In still another preferred embodiment, the capped poly(arylene ether)comprises at least one capping group having the structure

wherein A is a saturated or unsaturated C₂–C₁₂ divalent hydrocarbongroup such as, for example, ethylene, 1,2-propylene, 1,3-propylene,2-methyl-1,3-propylene, 2,2-dimethyl-1,3-propylene, 1,2-butylene,1,3-butylene, 1,4-butylene, 2-methyl-1,4-butylene,2,2-dimethyl-1,4-butylene, 2,3-dimethyl-1,4-butylene, vinylene(—CH═CH—), 1,2-phenylene, and the like. These capped poly(arylene ether)resins may conveniently be prepared, for example, by reaction of anuncapped poly(arylene ether) with a cyclic anhydride capping agent. Suchcyclic anhydride capping agents include, for example, maleic anhydride,succinic anhydride, glutaric anhydride, adipic anhydride, phthalicanhydride, and the like.

There is no particular limitation on the method by which the cappedpoly(arylene ether) is prepared. The capped poly(arylene ether) may beformed by the reaction of an uncapped poly(arylene ether) with a cappingagent. Capping agents include compounds known in the literature to reactwith phenolic groups. Such compounds include both monomers and polymerscontaining, for example, anhydride, acid chloride, epoxy, carbonate,ester, isocyanate, cyanate ester, or alkyl halide radicals. Cappingagents are not limited to organic compounds as, for example, phosphorusand sulfur based capping agents also are included. Examples of cappingagents include, for example, acetic anhydride, succinic anhydride,maleic anhydride, salicylic anhydride, polyesters comprising salicylateunits, homopolyesters of salicylic acid, acrylic anhydride, methacrylicanhydride, glycidyl acrylate, glycidyl methacrylate, acetyl chloride,benzoyl chloride, diphenyl carbonates such as di(4-nitrophenyl)carbonate, acryloyl esters, methacryloyl esters, acetyl esters,phenylisocyanate, 3-isopropenyl-alpha,alpha-dimethylphenylisocyanate,cyanatobenzene, 2,2-bis(4-cyanatophenyl)propane),3-(alpha-chloromethyl)styrene, 4-(alpha-chloromethyl) styrene, allylbromide, and the like, carbonate and substituted derivatives thereof,and mixtures thereof. These and other methods of forming cappedpoly(arylene ether)s are described, for example, in U.S. Pat. No.3,375,228 to Holoch et al.; U.S. Pat. No. 4,148,843 to Goossens; U.S.Pat. Nos. 4,562,243, 4,663,402, 4,665,137, and 5,091,480 to Percec etal.; U.S. Pat. Nos. 5,071,922, 5,079,268, 5,304,600, and 5,310,820 toNelissen et al.; U.S. Pat. No. 5,338,796 to Vianello et al.; andEuropean Patent No. 261,574 B1 to Peters et al.

In a preferred embodiment, the capped poly(arylene ether) may beprepared by reaction of an uncapped poly(arylene ether) with ananhydride in an alkenyl aromatic monomer as solvent. This approach hasthe advantage of generating the capped poly(arylene ether) in a formthat can be immediately blended with other components to form a curablecomposition; using this method, no isolation of the capped poly(aryleneether) or removal of unwanted solvents or reagents is required.

A capping catalyst may be employed in the reaction of an uncappedpoly(arylene ether) with an anhydride. Examples of such compoundsinclude those known to the art that are capable of catalyzingcondensation of phenols with the capping agents described above. Usefulmaterials are basic compounds including, for example, basic compoundhydroxide salts such as sodium hydroxide, potassium hydroxide,tetraalkylammonium hydroxides, and the like; tertiary alkylamines suchas tributyl amine, triethylamine, dimethylbenzylamine,dimethylbutylamine and the like; tertiary mixed alkyl-arylamines andsubstituted derivatives thereof such as N,N-dimethylaniline;heterocyclic amines such as imidazoles, pyridines, and substitutedderivatives thereof such as 2-methylimidazole, 2-vinylimidazole,4-(dimethylamino)pyridine, 4-(1-pyrrolino)pyridine,4-(1-piperidino)pyridine, 2-vinylpyridine, 3-vinylpyridine,4-vinylpyridine, and the like. Also useful are organometallic salts suchas, for example, tin and zinc salts known to catalyze the condensationof, for example, isocyanates or cyanate esters with phenols. Theorganometallic salts useful in this regard are known to the art innumerous publications and patents well known to those skilled in thisart.

The functionalized poly(arylene ether) may be a ring-functionalizedpoly(arylene ether). A ring-functionalized poly(arylene ether) isdefined herein as a poly(arylene, ether) comprising repeating structuralunits of the formula

wherein each L¹–L⁴ is independently hydrogen, an alkenyl group, or analkynyl group; wherein the alkenyl group is represented by

wherein L⁵–L⁷ are independently hydrogen or methyl, and a is an integerfrom 1 to 4; wherein the alkynyl group is represented by

CH₂

_(b)C≡C-L⁸wherein L⁸ is hydrogen, methyl, or ethyl, and b is an integer from 1 to4; and wherein about 0.02 mole percent to about 25 mole percent of thetotal L¹–L⁴ substituents in the ring-functionalized poly(arylene ether)are alkenyl and/or alkynyl groups. Within this range, it may bepreferred to have at least about 0.1 mole percent, more preferably atleast about 0.5 mole percent, alkenyl and/or alkynyl groups. Also withinthis range, it may be preferred to have up to about 15 mole percent,more preferably up to about 10 mole percent, alkenyl and/or alkynylgroups.

The ring-functionalized poly(arylene ether) may be prepared according toknown methods. For example, an unfunctionalized poly(arylene ether) suchas poly(2,6-dimethyl-1,4-phenylene ether) may be metalized with areagent such as n-butyl lithium and subsequently reacted with an alkenylhalide such as allyl bromide and/or an alkynyl halide such as propargylbromide. This and other methods for preparation of ring-functionalizedpoly(arylene ether) resins are described, for example, in U.S. Pat. No.4,923,932 to Katayose et al.

It will be understood that the poly(arylene ether)s described herein as“uncapped” or “unfunctionalized” comprise repeating structural unitshaving the formula

wherein for each structural unit, each Z¹ is independently hydrogen,halogen, primary or secondary C₁–C₁₂ alkyl, C₁–C₁₂ aminoalkyl, C₁–C₁₂hydroxyalkyl, phenyl, C₁–C₁₂ haloalkyl, C₁–C₁₂ hydrocarbonoxy, C₁–C₁₂halohydrocarbonoxy wherein at least two carbon atoms separate thehalogen and oxygen atoms, or the like; and each Z² is independentlyhalogen, primary or secondary C₁–C₁₂ alkyl, C₁–C₁₂ aminoalkyl, C₁–C₁₂hydroxyalkyl, phenyl, C₁–C₁₂ haloalkyl, C₁–C₁₂ hydrocarbonoxy, C₁–C₁₂halohydrocarbonoxy wherein at least two carbon atoms separate thehalogen and oxygen atoms, or the like. Preferably, each Z¹ isC₁₋₄-alkyl, and each Z² is hydrogen or methyl.

There is no particular limitation on the molecular weight or intrinsicviscosity of the functionalized poly(arylene ether). In one embodiment,the composition may comprise a functionalized poly(arylene ether) havinga number average molecular weight up to about 10,000 atomic mass units(AMU), preferably up to about 5,000 AMU, more preferably up to about3,000 AMU. Such a functionalized poly(arylene ether) may be useful inpreparing and processing the composition by reducing its viscosity.

In another embodiment, the composition may comprise a functionalizedpoly(arylene ether) having an intrinsic viscosity of about 0.08 to about0.30 deciliters per gram (dL/g), preferably about 0.12 to about 0.30dL/g, more preferably about 0.20 to about 0.30 dL/g as measured inchloroform at 25° C. Generally, the intrinsic viscosity of afunctionalized poly(arylene ether) will vary insignificantly from theintrinsic viscosity of the corresponding unfunctionalized poly(aryleneether). Specifically, the intrinsic viscosity of a functionalizedpoly(arylene ether) will generally be within 10% of that of theunfunctionalized poly(arylene ether). These intrinsic viscosities maycorrespond approximately to number average molecular weights of about5,000 to about 25,000 AMU. Within this range, a number average molecularweight of at least about 8,000 AMU may be preferred, and a numberaverage molecular weight of at least about 10,000 AMU may be morepreferred. Also within this range, a number average molecular weight upto about 20,000 AMU may be preferred. Such a functionalized poly(aryleneether) may provide the composition with a desirable balance of toughnessand processability. It is expressly contemplated to employ blends of atleast two functionalized poly(arylene ether)s having different molecularweights and intrinsic viscosities.

In a preferred embodiment, the functionalized poly(arylene ether) issubstantially free of amino substituents, including alkylamino anddialkylamino substituents, wherein substantially free means that thefunctionalized poly(arylene ether) contains less than about 300micrograms, preferably less than about 100 micrograms, of atomicnitrogen per gram of functionalized poly(arylene ether). Although manypoly(arylene ether)s are synthesized by processes that result in theincorporation of amino substituents, the present inventors have foundthat thermoset curing rates are increased when the functionalizedpoly(arylene ether) is substantially free of amino substituents.Poly(arylene ether)s substantially free of amino substituents may besynthesized directly or generated by heating amino-substitutedpoly(arylene ether)s to at least about 200° C. Alternatively, if thefunctionalized poly(arylene ether) contains amino substituents, it maybe desirable to cure the composition at a temperature less than about200° C.

The composition may comprise a blend of at least two functionalizedpoly(arylene ethers). Such blends may be prepared from individuallyprepared and isolated functionalized poly(arylene ethers).Alternatively, such blends may be prepared by reacting a singlepoly(arylene ether) with at least two functionalizing agents. Forexample, a poly(arylene ether) may be reacted with two capping agents,or a poly(arylene ether) may be metalized and reacted with twounsaturated alkylating agents. In another alternative, a mixture of atleast two poly(arylene ether) resins may be reacted with a singlefunctionalizing agent.

The composition may comprise the functionalized poly(arylene ether) inan amount of comprising about 10 to about 90 parts by weight per 100parts by weight total of the functionalized poly(arylene ether), thealkenyl aromatic monomer, the acryloyl monomer, and the polymericadditive. Within this range, it may be preferred to use a functionalizedpoly(arylene ether) amount of at least about 20 parts by weight, morepreferably at least about 30 parts by weight. Also within this range, itmay be preferred to use a functionalized poly(arylene ether) amount ofup to about 80 parts by weight, more preferably up to about 70 parts byweight, yet more preferably up to about 60 parts by weight, still morepreferably up to about 50 parts by weight.

The composition further comprises an alkenyl aromatic monomer. Thealkenyl aromatic monomer may have the structure

wherein each R¹⁶ is independently hydrogen, C₁–C₁₂ alkyl, C₁–C₁₂alkenyl, C₂–C₁₂ alkynyl, C₆–C₁₈ aryl, or the like; each R¹⁷ isindependently halogen, C₁–C₁₂ alkyl, C₁–C₁₂ alkoxyl, C₆–C₁₈ aryl, or thelike; p is 1 to 4; and q is 0 to 5. When p=1, the alkenyl aromaticmonomer is termed a monofunctional alkenyl aromatic monomer; when p=2–4,the alkenyl aromatic monomer is termed a polyfunctional alkenyl aromaticmonomer. Suitable alkenyl aromatic monomers include styrene,alpha-methylstyrene, alpha-ethylstyrene, alpha-isopropylstyrene,alpha-tertiary-butylstyrene, alpha-phenylstyrene, and the like;halogenated styrenes such as chlorostyrene, dichlorostyrene,trichlorostyrene, bromostyrene, dibromostyrene, tribromostyrene,fluorostyrene, difluorostyrene, trifluorostyrene, tetrafluorostyrene,pentafluorostyrene, and the like; halogenated alkylstyrenes such aschloromethylstyrene, and the like; alkoxystyrenes such asmethoxystyrene, ethoxystyrene, and the like; polyfunctional alkenylaromatic monomers such as 1,2-divinylbenzene, 1,3-divinylbenzene,1,4-divinylbenzene, trivinylbenzenes, 1,3-diisopropenylbenzene,1,4-diisopropenylbenzene, and the like; and mixtures comprising at leastone of the foregoing alkenyl aromatic monomers. In the foregoingsubstituted styrenes for which no substituent position is specified, thesubstituents may occupy any free position on the aromatic ring.

Preferred alkenyl aromatic monomers include styrene,alpha-methylstyrene, 2-methylstyrene, 3-methylstyrene, 4-methylstyrene,2-t-butylstyrene, 3-t-butylstyrene, 4-t-butylstyrene,1,3-divinylbenzene, 1,4-divinylbenzene, 1,3-diisopropenylbenzene,1,4-diisopropenylbenzene, and the like, and mixtures comprising at leastone of the foregoing alkenyl aromatic monomers. Preferred alkenylaromatic monomers further include styrenes having from 1 to 5 halogensubstituents on the aromatic ring, and mixtures comprising at least onesuch halogenated styrene.

Alkenyl aromatic monomers are commercially available from numeroussources. They may also be prepared by methods known in the art.

The composition may comprise the alkenyl aromatic monomer in an amountof about 10 to about 90 parts by weight per 100 parts by weight total ofthe functionalized poly(arylene ether), the alkenyl aromatic monomer,the acryloyl monomer, and the polymeric additive. Within this range, itmay be preferred to use an alkenyl aromatic monomer amount of at leastabout 20 parts by weight, more preferably at least about 30 parts byweight. Also within this range, it may be preferred to use an alkenylaromatic monomer amount of up to about 80 parts by weight, morepreferably up to about 70 parts by weight, yet more preferably up toabout 60 parts by weight, still more preferably up to about 50 parts byweight.

The composition further comprises an acryloyl monomer. The acryloylmonomer comprises at least one acryloyl moiety having the structure

wherein R¹⁸ and R¹⁹ are each independently hydrogen, C₁–C₁₂ alkyl, orthe like; and wherein R¹⁸ and R¹⁹ may be disposed either cis or transabout the carbon-carbon double bond. Preferably, R¹⁸ and R¹⁹ are eachindependently hydrogen or methyl. In one embodiment, the acryloylmonomer comprises at least two acryloyl moieties having the abovestructure and is termed a polyfunctional acryloyl monomer. In anotherembodiment, the acryloyl monomer comprises at least three acryloylmoieties having the above structure.

In one embodiment, the acryloyl monomer comprises at least one acryloylmoiety having the structure

wherein R²⁰–R²² are each independently hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂alkenyl, C₆–C₁₈ aryl, C₇–C₁₈ alkyl-substituted aryl, C₇–C₁₈aryl-substituted alkyl, C₂–C₁₂ alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl,C₈–C₁₈ alkyl-substituted aryloxycarbonyl, C₈–C₁₈ aryl-substitutedalkoxycarbonyl, nitrile, formyl, carboxylate, imidate, thiocarboxylate,or the like. Preferably, R²⁰–R²² are each independently hydrogen ormethyl. In one embodiment, the acryloyl monomer comprises at least twoacryloyl moieties having the structure above. In another embodiment, theacryloyl monomer comprises at least three acryloyl moieties having thestructure above.

Many additional suitable acryloyl monomers are described in U.S.Published Application No. 2001/0053820 A1 to Yeager et al.

In a preferred embodiment, the acryloyl monomer may include compoundshaving at least two acryloyl moieties per molecule, more preferably atleast three acryloyl moieties per molecule. Illustrative examplesinclude compounds produced by condensation of an acrylic or methacrylicacid with a di-epoxide, such as bisphenol-A diglycidyl ether, butanedioldiglycidyl ether, or neopenylene glycol dimethacrylate. Specificexamples include 1,4-butanediol diglycidylether di(meth)acrylate,bisphenol A diglycidylether dimethacrylate, and neopentylglycoldiglycidylether di(meth)acrylate, and the like. Also included asacryloyl monomers are the condensation of reactive acrylate ormethacrylate compounds with alcohols or amines to produce the resultingpolyfunctional acrylates or polyfunctional acrylamides. Examples includeN,N-bis(2-hydroxyethyl)(meth)acrylamide, methylenebis((meth)acrylamide),1,6-hexamethylenebis((meth)acrylamide), diethylenetriaminetris((meth)acrylamide), bis (gamma-((meth)acrylamide)propoxy) ethane,beta-((meth)acrylamide) ethylacrylate, ethylene glycoldi((meth)acrylate)), diethylene glycol di(meth)acrylate, tetraethyleneglycol di(meth)acrylateglycerol di(meth)acrylate, glyceroltri(meth)acrylate, 1,3-propylene glycol di(meth)acrylate,dipropyleneglycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate,1,2,4-butanetriol tri(meth)acrylate, 1,6-hexanediol di(meth)acrylate,1,4-cyclohexanediol di(meth)acrylate, 1,4-benzenediol di(meth)acrylate,pentaerythritoltetra(meth)acrylate, 1,5-pentanediol di(meth)acrylate,trimethylolpropane di(meth)acrylate, trimethylolpropanetri(meth)acrylate), 1,3,5-triacryloylhexahydro-1,3,5-triazine,2,2-bis(4-(2-(meth)acryloxyethoxy)phenyl)propane,2,2-bis(4-(2-(meth)acryloxyethoxy)-3,5-dibromophenyl)propane,2,2-bis((4-(meth)acryloxy)phenyl)propane,2,2-bis((4-(meth)acryloxy)-3,5-dibromophenyl)propane, and the like, andmixtures comprising at least one of the foregoing acryloyl monomers. Itwill be understood that the fragment “(meth)acryl-” denotes either“acryl-” or “methacryl-”.

Highly preferred acryloyl monomers include trimethylolpropanetri(meth)acrylate, 1,6-hexanediol di(meth)acrylate, ethylene glycoldi(meth)acrylate, propylene glycol di(meth)acrylate,cyclohexanedimethanol di(meth)acrylate, butanediol di(meth)acrylate,diethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate,isobornyl(meth)acrylate, cyclohexyl (meth)acrylate, butyl(meth)acrylate,methyl (meth)acrylate, dibutyl fumarate, dibutyl maleate, glycidyl(meth)acrylate, ethyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, hexyl(meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, decyl(meth)acrylate, octyl (meth)acrylate, ethoxylated (3, 6, 9, 15, and 20)trimethylolpropane tri(meth)acrylate, propoxylated (3 and 6)trimethylolpropane tri (meth)acrylate, and the like, and mixturescomprising at least one of the foregoing acryloyl monomers.

Acryloyl monomers are commercially available from numerous sources. Theymay also be prepared by methods known in the art.

The composition may comprise the acryloyl monomer in an amount of about1 to about 50 parts by weight per 100 parts by weight total of thefunctionalized poly(arylene ether), the alkenyl aromatic monomer, theacryloyl monomer, and the polymeric additive. Within this range, it maybe preferred to use an acryloyl monomer amount of at least about 5 partsby weight, more preferably at least about 10 parts by weight. Alsowithin this range, it may be preferred to use an acryloyl monomer amountof up to about 40 parts by weight, more preferably up to about 30 partsby weight, yet more preferably up to 20 parts by weight.

In one embodiment, in addition to the poly(arylene ether), thepoly(alkenyl aromatic) compound, and the acryloyl compound, thecomposition further comprises a polymeric additive having a glasstransition temperature less than or equal to 100° C. and a Young'smodulus less than or equal to 1000 MPa at 25° C.; wherein the polymericadditive is soluble in the combined functionalized poly(arylene ether),alkenyl aromatic monomer, and acryloyl monomer at a temperature lessthan or equal to 50° C.

It may be preferred that the polymeric additive is soluble in thecombined functionalized poly(arylene ether), alkenyl aromatic monomer,and acryloyl monomer at a temperature less than or equal to 40° C., morepreferably less than or equal to 30° C., still more preferably less thanor equal to 20° C. Another way of describing the solubility limitationis that the functionalized poly(arylene ether), the alkenyl aromaticmonomer, the acryloyl monomer, and the polymeric additive are capable ofcollectively forming a solution, preferably a substantially homogeneoussolution, at a temperature less than or equal to 50° C. By substantiallyhomogeneous solution, it is meant that the solution contains less than0.1% by weight of particles greater than 1 micrometer in any dimension.The solution preferably contains less than 0.01% by weight of particlesgreater than 1 micrometer in any dimension.

The polymeric additive has a glass transition temperature less than orequal to 100° C., preferably less than or equal to 75° C., morepreferably less than or equal to 50° C., even more preferably less thanor equal to 25° C., even more preferably less than or equal to 0° C.

The polymeric additive has a Young's modulus less than or equal to 1000MPa at 25° C., preferably less than or equal to 100 MPa at 25° C., morepreferably less than or equal to 10 MPa at 25° C.

In one embodiment, the polymeric additive is selected from the groupconsisting of poly(alkenyl hydrocarbon)s, poly(alkyl (meth)acrylate)s,poly(vinyl ester)s, polysiloxanes, and combinations comprising at leastone of the foregoing polymeric additives.

The polymeric additive may comprise a poly(alkenyl hydrocarbon).Suitable poly(alkenyl hydrocarbon)s include those comprising at least 80weight percent, preferably at least 90 weight percent, more preferablyat least 95 weight percent, still more preferably at least 98 weightpercent, of repeating structural units having the formula

wherein R²³–R²⁶ are each independently hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂alkenyl, C₆–C₁₈ aryl, C₇–C₁₈ aralkyl, or C₇–C₁₈ alkylaryl. In apreferred embodiment, R²³–R²⁶ are each independently hydrogen, C₁–C₁₂alkyl, or C₂–C₁₂ alkenyl. In one embodiment, the poly(alkenylhydrocarbon) is free of heteroatoms.

In one embodiment, the poly(alkenyl hydrocarbon) may comprisepolybutadiene; polyethylene; polypropylene; polybutene;poly(4-methyl-1-pentene); a block copolymer comprising a first blockthat is the polymerization product of styrene and/or alpha-methylstyrene and a second block that is the hydrogenated polymerizationproduct of butadiene and/or isoprene; or the like, or a combinationcomprising at least one of the foregoing polyolefins.

In another embodiment, the poly(alkenyl hydrocarbon) may comprisepolyethylenes, polypropylenes, poly(4-methyl-1-pentene)s,polybutadienes, carboxy-terminated polybutadienes, polyisobutenes,polyisoprenes, ethylene-propylene copolymers, ethylene-propylene-dieneterpolymers, styrene-butadiene copolymers, styrene-isoprene copolymers,isobutylene-isoprene copolymers, butadiene-isoprene copolymers, or thelike, or combinations comprising at least one of the foregoingpolyolefins.

Suitable poly(alkenyl hydrocarbon)s may be prepared according to methodswell known in the art, such as those described in, for example, U.S.Pat. No. 3,281,383 to Zelinski et al.; U.S. Pat. No. 3,595,942 to Waldet al., U.S. Pat. No. 4,230,767 to Isaka et al., U.S. Pat. No. 4,892,851to Ewen et al., U.S. Pat. No. 4,298,718 to Mayr et al., U.S. Pat. No.4,544,717 to Mayr et al., U.S. Pat. No. 4,794,096 to Ewen, U.S. Pat. No.4,975,403 to Ewen, U.S. Pat. No. 5,243,002 to Ravazi, U.S. Pat. No.5,308,811 to Suga et al., U.S. Pat. No. 5,444,134 to Matsumoto, and U.S.Pat. No. 6,090,872 to Albe et al. Suitable poly(alkenyl hydrocarbon)smay also be obtained from commercial suppliers, including, for example,the poly(ethylene-butylene)s sold by Kraton Polymers as KRATON® L1203and L2203; and the carboxy-terminated polybutadienes sold by NoveonSolutions as HYCAR® 2000X162 and HYCAR® 1300X31.

In one embodiment, the polymeric additive comprises a poly(alkyl(meth)acrylate). Suitable poly(alkyl (meth)acrylate)s include thosecomprising at least 80 weight percent, preferably at least about 90weight percent, more preferably at least about 95 weight percent, stillmore preferably at least about 98 weight percent, of repeatingstructural units having the formula

wherein each R²⁷ is independently hydrogen or methyl, and each R²⁸ isindependently C₁–C₁₂ alkyl. Preferably, R²⁸ is C₂–C₆ alkyl. It will beunderstood that the prefix “(meth)acryl-” signifies either “acryl-” or“methacryl-”.

Suitable poly(alkyl (meth)acrylate)s include, for example, poly(methylacrylate), poly(methyl methacrylate), poly(ethyl acrylate), poly(ethylmethacrylate), poly(butyl acrylate), poly(butyl methacrylate),poly(2-ethylhexyl acrylate), poly(2-hexyl acrylate), and the like, andcopolymers of the corresponding monomers, and combinations comprising atleast one of the foregoing poly(alkyl (meth)acrylate)s.

In one embodiment, the poly(alkyl (meth)acrylate) may comprisepoly(butyl acrylate), poly(2-hexyl acrylate), or the like, orcombinations comprising at least one of the foregoing poly(alkyl(meth)acrylate)s.

Suitable poly(alkyl (meth)acrylate)s may be prepared according tomethods known in the art, such as those described in, for example, U.S.Pat. No. 3,476,722 to Schlatzer, U.S. Pat. No. 4,081,418 to Barua etal., and U.S. Pat. No. 4,158,736 to Lewis et al. Suitable poly(alkyl(meth)acrylate)s may also be obtained from commercial suppliers,including, for example, a poly(methyl acrylate) having a weight averagemolecular weight of about 40,000 AMU and a glass transition temperatureof about 9° C., obtained from Aldrich Chemical as product number18221-4; a poly(ethyl acrylate) having a weight average molecular weightof about 95,000 AMU and a glass transition temperature of about −23° C.,obtained from Aldrich Chemical as product number 18188-9; and poly(butylacrylate) having a weight average molecular weight of about 99,000 AMUand a glass transition temperature of about −49° C., obtained fromAldrich Chemical as product number 18140-4.

In one embodiment, the polymeric additive comprises a poly(vinyl ester).Suitable poly(vinyl ester)s include those comprising at least 80 weightpercent, preferably at least about 90 weight percent, more preferably atleast about 95 weight percent, still more preferably at least about 98weight percent, of repeating structural units having the formula

wherein each R²⁹ is independently C₁–C₁₈ alkyl C₂–C₁₈ alkenyl, C₂–C₁₈alkynyl, C₆–C₁₈ aryl, C₇–C₁₈ alkylaryl, C₇–C₁₈ aralkyl, and the like,wherein each of the foregoing groups may, optionally, be substitutedwith one or more substituents including epoxy, hydroxy, amino, carboxyl,and the like. In one embodiment, each R²⁹ is independently C₁–C₁₈ alkyl.In one embodiment, each R²⁹ is independently C₃–C₁₂ alkyl, morepreferably C₃–C₁₀ alkyl, still more preferably C₃–C₇ alkyl. Highlypreferred poly(vinyl esters) include poly(vinyl acetate) and copolymersof vinyl acetate and an acid-containing vinyl compound, such as, forexample, methacrylic acid or crotonic acid.

The poly(vinyl ester) preferably has a number average molecular weightof about 1,000 to about 150,000 AMU. Within this range, the numberaverage molecular weight may be at least about 5,000 AMU, 7,000 AMU, or10,000 AMU. Also within this range, the number average molecular weightmay be up to about 100,000 AMU, 80,000 AMU, or 50,000 AMU.

Preferred poly(vinyl ester)s include polymers of vinyl propionate, vinylbutyrate, vinyl pentanoate, vinyl pivalate, vinyl hexanoate, vinyl2-ethylhexanoate, vinyl nonanate, vinyl neononanate, vinyl decanoate,vinyl dodecanoate (vinyl laurate), vinyl tetradecanoate (vinylmyristate), vinyl hexadecanoate (vinyl palmitate), vinyl octadecanoate(vinyl stearate), and the like, and mixtures comprising at least one ofthe foregoing monomers.

Poly(vinyl ester)s may be prepared by methods known in the art, such asthose described in, for example, M. K. Lindemann in G. E. Han, Ed.“Vinyl Polymerization”, Volume 1, Dekker: New York (1967), pages252–255; and K. K. Georgieff et al. J. Appl. Pol. Sci., 1964, volume 8,pages 889–896. Poly(vinyl ester)s may also be obtained commerciallyfrom, for example, LP40A, LP90, and NEULON® T from Union Carbide; thosesold under the ACRONAL®, ACROSOL, and STYRONAL® tradenames from BASF;DESMOPHEN® A from Bayer; those sold under the tradename SYNOCRYL® fromCray Valley; and those sold under the tradename DEGALAN® from Degussa.

In one embodiment, the polymeric additive is a copolymer comprising atleast about 80 weight percent, preferably at least about 90 weightpercent, more preferably at least about 95 weight percent, still morepreferably at least about 98 weight percent, of the polymerizationproduct of at least a first monomer type and a second monomer type,wherein the first monomer type and the second monomer type are differentand independently selected from the group consisting of alkenylhydrocarbons, alkyl(meth)acrylates, vinyl alkanoates, and nitriles. Inother words, the copolymers include two different monomer types (such asan alkenyl hydrocarbon and an alky(meth)acrylate), rather than twomonomers of the same type (such as two different alkenyl hydrocarbons).

Preferred copolymers may include, for example, butadiene-acrylonitrilecopolymers, carboxy-terminated butadiene-acrylonitrile copolymers, orthe like, or combinations comprising at least one of the foregoingcopolymers.

In one embodiment, the polymeric additive comprises abutadiene-acrylonitrile copolymer, a polychloroprene butadiene-styrenecopolymer, or a combination thereof.

In another embodiment, the polymeric additive may compriseethylene-vinyl acetate copolymers, ethylene-ethyl acrylate copolymers,acrylonitrile-butadiene-styrene terpolymers, acrylonitrile-butadienecopolymers, methyl methacrylate-butadiene-styrene terpolymers,ethylacrylate-acrylonitrile copolymers, maleic anhydride-graftedpolybutadienes, vinyl chloride-vinyl acetate-acrylic acid terpolymers,ethylene-vinyl acetate-acrylic acid terpolymers, or the like, orcombinations comprising at least one of the foregoing copolymers.

Suitable copolymers may be prepared according to methods well known inthe art, such as those described in, for example, U.S. Pat. No.5,053,496 to Bertsch et al., U.S. Pat. No. 5,157,077 to Siebert et al.,and U.S. Pat. No. 5,198,510 to Siebert et al. Suitable copolymers mayalso be obtained from commercial suppliers, including, for example, thecarboxy-terminated butadiene (90%)/acrylonitrile (10%) copolymer havinga carboxyl content acid number of 28, a solubility parameter of 8.14, anumber average molecular weight of 3,800 AMU, and a glass transitiontemperature of −66° C., obtained as HYCAR® 1300X31 CTBN from NoveonSolutions.

In one embodiment, the polymeric additive comprises a polysiloxane.Suitable polysiloxanes include those having the formula

wherein R³⁰–R³³ are each independently hydrogen, hydroxy, C₁–C₁₂ alkyl,C₁–C₁₂ alkoxy, C₂–C₁₂ alkenyl, C₂–C₁₂ alkynyl, C₆–C₁₈ aryl, C₇–C₁₈alkylaryl, and C₇–C₁₈ aralkyl, wherein each of the foregoing groups may,optionally, be substituted with one or more substituents selected fromthe group consisting of epoxy, hydroxy, cyano, amido, amino, andcarboxyl; and n is about 3 to about 10,000. Preferably, n is at least10, more preferably at least 100. In a preferred embodiment, R³⁰–R³³ areeach independently C₁–C₁₂ alkyl or C₂–C₁₂ alkenyl. Suitablepolysiloxanes further include graft and block copolymers formed from apre-formed polymer or oligomer (e.g., poly(ethylene oxide)s,poly(propylene oxides), poly(butylene oxides)o, or poly(alkenylhydrocarbons as described above) and the above described polysiloxanechain through condensation or hydrosilation.

Examples of suitable polysiloxanes include vinyl-terminatedpolydimethylsiloxanes, vinyl-terminateddiphenylsiloxane-dimethylsiloxane copolymers, vinyl-terminatedtrifluoropropylmethylsiloxane-diphenylsiloxane copolymers,vinyl-terminated diethylsiloxane-dimethylsiloxane copolymers,vinylmethylsiloxane-dimethylsiloxane copolymers,trimethylsiloxane-terminated vinylmethylsiloxane-dimethylsiloxanecopolymers, silanol-terminated vinyl methylsiloxane-dimethylsiloxanecopolymers, vinyl-terminated vinylsiloxane gums, vinylmethylsiloxanehomopolymers, vinylmethoxysiloxane homopolymers, hydride terminatedpolydimethylsiloxanes, methylhydrosiloxane-dimethylsiloxane copolymers,polymethylhydrosiloxanes, polyethylhydrosiloxanes, silanol-terminatedpolydimethylsiloxanes, aminopropyl-terminated polydimethylsiloxanes,aminopropylmethylsiloxane-dimethylsiloxane copolymers,polydimethylsiloxane-poly(ethyleneoxide) block copolymers,polydimethylsiloxane poly(propylene oxide-ethylene oxide) copolymers(e.g., with 50–70% poly(propylene oxide-ethylene oxide),cyanopropylmethylsiloxane-dimethylsiloxane copolymers,(N-pyridonepropyl) siloxane-dimethylsiloxane copolymers,epoxypropoxypropyl-terminated polydimethylsiloxanes,epoxycyclohexylethylmethylsiloxane-dimethylsiloxane copolymers,(meth)acryloxypropylmethylsiloxane-dimethylsiloxane copolymers, and thelike.

Preferred polysiloxanes include vinyl-terminated polydimethylsiloxanes.Other preferred polysiloxanes include hydroxy-terminatedpolydimethylsiloxanes. Polysiloxanes may be prepared by methods known inthe art, such as those described in, for example, U.S. Pat. No.3,996,195 to Sato et al., U.S. Pat. No. 4,257,936 to Matsumoto et al.,U.S. Pat. No. 4,855,351 to Stein, and U.S. Pat. No. 5,405,896 to Fujikiet al. Polysiloxanes may also be obtained commercially from, forexample, GE Silicones, a division of General Electric Company.

In one embodiment, the polysiloxane comprises a methyl siliconeoptionally substituted with phenyl and/or vinyl groups.

In one embodiment, in addition to the poly(arylene ether), thepoly(alkenyl aromatic) compound, and the acryloyl compound, thecomposition further comprises a polymeric additive selected from thegroup consisting of polystyrene, poly(styrene-maleic anhydride),poly(styrene-methyl methacrylate), polybutene, poly(ethylene-butylene),poly(vinyl ether), poly(vinyl acetate), and combinations comprising atleast one of the foregoing polymeric additives.

Suitable polystyrenes for use as the polymeric additive includehomopolymers and copolymers comprising at least about 80 weight percent,preferably at least about 90 weight percent, more preferably at leastabout 95 weight percent, still more preferable at least about 98 weightpercent, of repeating structural units having the formula

wherein R³⁴ is hydrogen, C₁–C₈ alkyl, halogen, or the like; Z is vinyl,halogen, C₁–C₈ alkyl, or the like; and p is 0 to 5. Preferred alkenylaromatic monomers include styrene, chlorostyrenes such asp-chlorostyrene, and methylstyrenes such as p-methylstyrene. In additionto homopolymers and copolymers of the above alkenyl aromatic monomers,polystyrenes may further comprise copolymers further comprising up to10% by weight of other copolymerizable monomers, such as, for example,acrylonitrile, butadiene, and maleic anhydride. A preferred polystyreneis a homopolymer of styrene having a number average molecular weight ofabout 10,000 to about 400,000 atomic mass units (AMU). The polystyrenemay be atactic, syndiotactic, or isotactic, with atactic polystyrenebeing preferred. Suitable polystyrenes may be prepared by methods knownin the art, including those described, for example, in U.S. Pat. No.3,280,089 to Wright. Suitable polystyrenes may also be obtainedcommercially as, for example, DYLARK® 1200 and 1600 from Nova Chemical;polystyrene in styrene solution N715 from AOC Resins; the polystyrenehaving a weight average molecular weight of 280,000 and a glasstransition temperature of 100° C. available under catalog number18,242-7 from Aldrich Chemical; and various polystyrenes available fromPolysciences Inc.

Poly(styrene-maleic anhydride) copolymers suitable for use as thepolymeric additive include random copolymers of styrene and maleicanhydride having a styrene content of about 50 to about 95 weightpercent and a maleic anhydride content of about 5 to about 50 weightpercent. Such copolymers may be prepared by known methods, includingthose described, for example, in U.S. Pat. No. 3,404,135 to Tietz. Theymay also be obtained commercially as, for example, SMA® resins fromSartomer Company, such as SMA® 1000 having a weight average molecularweight of 5500 AMU, a glass transition temperature of 155° C., and acidnumber of 465–495; and the poly(styrene-maleic anhydride) having 14weight percent maleic anhydride and a glass transition temperature of132° C. available under catalog number 42,695-4 from Aldrich ChemicalCo.

Poly(styrene-methyl methacrylate) copolymers suitable for use as thepolymeric additive include random copolymers of styrene and methylmethacrylate having a styrene content of about 25 to about 90 weightpercent and a methyl methacrylate content of about 10 to about 75 weightpercent. Such copolymers may be prepared by known methods, such as thosedescribed in, for example, U.S. Pat. No. 4,680,352 to Janowicz et al.The poly(styrene-methyl methacrylate) copolymers may also be obtainedcommercially as, for example, NAS® resin 21 having a melt flow rate of1.9 g/10 min measured at 200° C. and 5 kg according to ASTM D1238, and aVicat softening temperature of 106° C. measured according to D1525,available from Nova Chemical Company; NAS® resin 30 having a melt flowrate of 2.2 g/10 min measured at 200° C. and 5 kg according to ASTMD1238, and a Vicat softening temperature of 104° C. measured accordingto D1525, available from Nova Chemical Company; and thepoly(styrene-co-methylmethacrylate) having about 40 weight percentstyrene, a weight average molecular weight of about 100,000–150,000 AMU,and a glass transition temperature of 101° C., available under catalognumber 46,289-6 from Aldrich Chemical Co.

Polybutenes suitable for use as the polymeric additive includehomopolymers and copolymers of 1-butene, 2-butene, and isobutene. Thepolybutene may preferably have a number average molecular weight ofabout 150 to about 3,000 atomic mass units (AMU). Even more preferably,the polybutene has a number average molecular weight greater than orequal to about 300 atomic mass units. Polybutenes may be preparedaccording to known methods such as those described in, for example, U.S.Pat. No. 3,808,286 to Olund. They may also be obtained commercially as,for example, INDOPOL® Polybutenes L-4, L-6, L-10, L-14, H-15, H-25,H-35, H-40, H-50, H-100, H-300, H-1500, H-1900 from Amoco (thesematerials have number average molecular weights ranging from about 180to about 2,500, polydispersity indices ranging from about 1 to about 2,and glass transition temperatures less than −65° C.); and PARAPOL®Polybutenes 450, 700, 950, 1300, 2350, and 2700 from ExxonMobilChemical.

In another embodiment, the curable composition comprises a polybutenewherein the curable composition forms a sol-gel having a sol-geltransition temperature preferably greater than about 60° C., morepreferably greater than or equal to about 75° C., and even morepreferably greater than or equal to about 90° C. “Sol-gel” as definedherein is as a multiphase system that is nonflowing. The multiphasesystem can be described as a bicontinuous structure or an interconnectednetwork. One phase of the bicontinuous structure may be described as the“scaffolding” and the other phase is interwoven within the scaffolding.As seen in FIG. 3, a confocal microscopy image shows the structure ornetwork of a sol-gel having a first phase (10) and a second phase (20).The first and the second phases can be seen interwoven with one another.Upon heating above the sol-gel transition temperature (T_(sol-gel)), theinterconnected network dissolves and the system becomes miscible (thatis, single phase). The sol-gel transition temperature is the temperaturebelow which the system phases separate and form an interconnectednetwork, and above which the system phases become miscible and the geldissolves into a flowing liquid. Sol-gel transition temperatures as highas 105° C. may be achieved. In a non-limiting example, a sol-gel may beformed from a curable composition comprising a functionalizedpoly(arylene ether), an alkenyl aromatic monomer, an acryloyl monomer,and a polybutene.

The curable composition sol-gels are believed to provide good glasscarry and uniform glass bundle distribution when molded. Molding is adynamic process where the uncured composition is simultaneously pressedand heated. The sol-gels retain greater viscosity in this transientprocess than a non-gelled analogue. It is believed that this retentionof viscosity allows the resin to carry and push the glass fibercomponent of the composite to all parts of a molded object.Additionally, it is believed that the shear forces transferred by thehigher viscosity resin helps to break apart individual fibers from glassbundles and thereby improve their distribution in the molded part.

Suitable polybutenes to create a curable composition sol-gel having asol-gel transition temperature greater than about 60° C. includehomopolymers and copolymers of 1-butene, 2-butene, and isobutene havinga number average molecular weight greater than or equal to about 300atomic mass units (AMU) and less than or equal to about 1000 AMU,preferably greater than or equal to about 500 AMU and less than or equalto 800 AMU. Polybutenes having number average molecular weights of above1000 AMU may be used although increasing viscosities may make processingdifficult. Suitable commercially available polybutenes include INDOPOL®Polybutenes L-10, L-14, H-15, H-25, H-35, H-40, H-50, and H-100 fromAmoco.

Preferred amounts of polybutenes for the sol-gel curable compositionsmay be about 0.1 to about 30 parts by weight per 100 parts by weighttotal of the functionalized poly(arylene ether), the alkenyl aromaticmonomer, the acryloyl monomer, and the polybutene. Within this range,the amount of polybutene may be at least about 1, or at least about 5parts by weight per 100 parts by weight total of the functionalizedpoly(arylene ether), the alkenyl aromatic monomer, the acryloyl monomer,and the polybutene. Also within this range, the amount of polybutene maybe up to about 10, or up to about 20 parts by weight per 100 parts byweight total of the functionalized poly(arylene ether), the alkenylaromatic monomer, the acryloyl monomer, and the polybutene.

Poly(ethylene-butylene) copolymers suitable for use as the polymericadditive include random and block copolymers having an ethylene contentof about 1 to about 99 weight percent and a butylene content of about 99to about 1 weight percent. Butylene is herein defined as 1-butene. Inaddition to ethylene and butylene, the poly(ethylene-butylene) mayinclude up to 10 weight percent of other monomers and functionalizingagents. For example, the poly(ethylene-butylene) may be a monohydroxy-or dihydroxy-terminated poly(ethylene-butylene) or a monocarboxy- ordicarboxy-terminated poly(ethylene-butylene). Thepoly(ethylene-butylene) copolymer may preferably have a number averagemolecular weight of about 1,000 to about 5,000 AMU. Suitablepoly(ethylene-butylene) copolymers may be prepared according to knownmethods, such as polymerization of butadiene followed by hydrogenation.Suitable poly(ethylene-butylene) copolymers may also be obtainedcommercially as, for example, KRATON® L1203 from Kraton Polymers havinga number average molecular weight of about 4,200; and KRATON® L2203 fromKraton Polymers having number average molecular weight of about 1,700.

Poly(vinyl ether) resins suitable for use as the polymeric additiveinclude those comprising at least about 80 weight percent, preferably atleast about 90 weight percent, more preferably at least about 95 weightpercent, still more preferably at least about 98 weight percent, ofrepeating structural units having the formula

wherein R³⁵ is C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₆–C₁₈ aryl, C₇–C₁₈alkylaryl, C₇–C₁₈ aralkyl, or the like. In a preferred embodiment, R³⁹is C₁–C₁₂ alkyl. Preferred poly(vinyl ether) resins include, forexample, poly(ethyl vinyl ether), poly(isobutyl vinyl ether),poly(cyclohexyl vinyl ether), and the like, copolymers of thecorresponding vinyl ethers, and combinations comprising at least one ofthe foregoing poly(vinyl ethers). The poly(vinyl ether) may preferablyhave a number average molecular weight of about 3,000 to about 150,000AMU. Within this range, a number molecular weight of at least about10,000 AMU may be preferred. Also within this range, a number averagemolecular weight of up to about 100,000 AMU may be preferred. Thepoly(vinyl ether) may preferably have a glass transition temperatureless than or equal to 20° C., more preferably less than or equal to 0°C. Poly(vinyl ether) resins may be prepared according to methods knownin the art (e.g., U.S. Pat. No. 5,691,430 to Dougherty et al.) orobtained commercially as, for example, those sold under the tradenameLUTENOL® from BASF, such as the poly(vinyl methyl ether) sold asLUTENOL® M, the poly(vinyl ethyl ether) sold as LUTENOL® A, thepoly(vinyl isobutyl ether) sold as LUTENOL® I, and the poly(vinyloctadecyl ether) sold as LUWAX® V.

Poly(vinyl acetate) resins suitable for use as the polymeric additiveinclude vinyl acetate homopolymers having a number average molecularweight of about 3,000 to about 150,000 AMU. Within this range, thenumber average molecular weight may preferably be at least about 10,000.Also within this range, the number average molecular weight maypreferably be up to about 100,000 AMU. The poly(vinyl acetate) maypreferably have a glass transition temperature less than or equal toabout 70° C. Poly(vinyl acetate) resins may be prepared according toknown methods (e.g., U.S. Pat. No. 3,285,895 to MacKenzie et al.) orobtained commercially as, for example, the carboxylated poly(vinylacetate) provided as a 40 weight percent polymer solution in styrene,sold as LP40A by Dow (formerly sold by Union Carbide); anon-carboxylated poly(vinyl acetate) provided as a 40 weight percentpolymer solution in styrene and sold as LP90 by Dow; a poly(vinylacetate) copolymer provided as a 40 weight percent polymer solution instyrene and sold as NEULON® T by Dow.

In one preferred embodiment, the polymeric additive comprises apoly(vinyl ether). In another preferred embodiment, the polymericadditive comprises a poly(ethylene-butylene).

The polymeric additive may be used in an amount of about 0.1 to about 30weight percent of the polymeric additive, based on the total weight ofthe functionalized poly(arylene ether), the alkenyl aromatic monomer,the acryloyl monomer, and the polymeric additive. Within this range itmay be preferred to use a polymeric additive amount of at least about0.5 weight percent, more preferably at least about 1 weight percent, yetmore preferably at least about 2 weight percent, still more preferablyat least about 5 weight percent, even more preferably at least about 8weight percent. Also within this range, it may be preferred to use apolymeric additive amount of up to about 25 weight percent, morepreferably up to about 20 weight percent, still more preferably up toabout 15 weight percent. In general, it is preferred to use a polymericadditive amount that is less than the so-called critical point of thecomposition. The critical composition defines the additive level abovewhich the phase separated additive changes from being a minor, dispersedphase, into being a continuous phase. The critical composition for abinary blend can be estimated using a thermodynamically derived equationand the component specific volumes (i.e., molecular weight/density). Fora multi-component base resin, an average specific volume can beestimated. The critical volume fraction composition of component 1 iscalculated as the reciprocal of the quantity 1 plus the square root ofthe ratio of component 1 specific volume over component 2 specificvolume, as described in T. A. Callaghan, and D. R. Paul, Macromolecules(1993), volume 26, pages 2439–2450; and I. C. Sanchez, Polymer (1989),volume 30, pages 471–475.

In one embodiment, the polymeric additive may comprise a first polymericadditive comprising polystyrene, poly(styrene-maleic anhydride),poly(styrene-methyl methacrylate), polybutene, poly(ethylene-butylene),poly(vinyl ether), poly(vinyl acetate), and combinations comprising atleast one of the foregoing polymeric additives; and a second polymericadditive selected from polybutadienes, polyacrylates,styrene-acrylonitrile copolymers, styrene-butadiene block and randomcopolymers, hydrogenated styrene-butadiene diblock copolymers,styrene-butadiene-styrene triblock copolymers, hydrogenatedstyrene-butadiene-styrene triblock copolymers, styrene-isoprene-styrenetriblock copolymers, hydrogenated styrene-isoprene-styrene triblockcopolymers, ethylene-propylene-diene terpolymers, and the like, andcombinations comprising at least one of the foregoing second polymericadditives. These and other second polymeric additives are described inU.S. Published Application No. 2001/0053820 A1 to Yeager et al. Thesecond polymeric additive may be used in an amount of about 0.1 to about30 weight percent, based on the total weight of the functionalizedpoly(arylene ether), the alkenyl aromatic monomer, the acryloyl monomer,the first polymeric additive, and the second polymeric additive.

In a highly preferred embodiment, the composition comprises apoly(ethylene-butylene) as the polymeric additive and a polybutadiene asthe second polymeric additive. The polybutadiene may preferably have anumber average molecular weight of about 1,000 to about 10,000 AMU.Within this range, the number average molecular weight may be at leastabout 2,000 AMU, or 3,000 AMU. Also within this range, the numberaverage molecular weight may be up to about 9,000 AMU, or 8,000 AMU.

The composition may, optionally, further comprise a curing catalyst toincrease the curing rate of the unsaturated components. Curingcatalysts, also referred to as initiators, are well known to the art andused to initiate the polymerization, cure or crosslink any of numerousthermoplastics and thermosets including unsaturated polyester, vinylester and allylic thermosets. Non-limiting examples of curing catalystsare those described in “Plastic Additives Handbook, 4^(th) Edition” R.Gachter and H. Muller (eds.), P. P. Klemchuck (assoc. ed.) HansenPublishers, New York 1993, and in U.S. Pat. No. 5,407,972 to Smith etal., and U.S. Pat. No. 5,218,030 to Katayose et al. The curing catalystfor the unsaturated portion of the thermoset may include any compoundcapable of producing radicals at elevated temperatures. Such curingcatalysts may include both peroxy and non-peroxy based radicalinitiators. Examples of useful peroxy initiators include, for example,benzoyl peroxide, dicumyl peroxide, methyl ethyl ketone peroxide, laurylperoxide, cyclohexanone peroxide, t-butyl hydroperoxide, t-butyl benzenehydroperoxide, t-butyl peroctoate,2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(t-butylperoxy)-hex-3-yne, di-t-butylperoxide,t-butylcumyl peroxide,alpha,alpha′-bis(t-butylperoxy-m-isopropyl)benzene,2,5-dimethyl-2,5-di(t-butylperoxy)hexane, dicumylperoxide,di(t-butylperoxy isophthalate, t-butylperoxybenzoate,2,2-bis(t-butylperoxy)butane, 2,2-bis(t-butylperoxy)octane,2,5-dimethyl-2,5-di(benzoylperoxy)hexane, di (trimethylsilyl)peroxide,trimethylsilylphenyltriphenylsilyl peroxide, and the like, and mixturescomprising at least one of the foregoing curing catalysts. Typicalnon-peroxy initiators include, for example,2,3-dimethyl-2,3-diphenylbutane,2,3-trimethylsilyloxy-2,3-diphenylbutane, and the like, and mixturescomprising at least one of the foregoing curing catalysts. The curingcatalyst for the unsaturated portion of the thermoset may furtherinclude any compound capable of initiating anionic polymerization of theunsaturated components. Such anionic polymerization catalysts include,for example, alkali metal amides, such as sodium amide (NaNH₂) andlithium diethyl amide (LiN(C₂H₅)₂); alkali metal and ammonium salts ofC₁–C₁₀ alkoxides; alkali metal and ammonium hydroxides; alkali metalcyanides; organometallic compounds such as the alkyl lithium compoundn-butyl lithium and the grignard reagent phenyl magnesium bromide; andthe like; and combinations comprising at least one of the foregoinganionic polymerization catalysts.

In a preferred embodiment, the curing catalyst may compriset-butylperoxybenzoate or methyl ethyl ketone peroxide. The curingcatalyst may promote curing at a temperature of about 0° C. to about200° C.

When present, the curing catalyst may be used in an amount of about 0.1to about 10 parts by weight per 100 parts total of the functionalizedpoly(arylene ether), the alkenyl aromatic monomer, the acryloyl monomer,and the polymeric additive. Within this range, it may be preferred touse a curing catalyst amount of at least about 0.5 parts by weight, morepreferably at least about 1 part by weight. Also within this range, itmay be preferred to use a curing catalyst amount of up to about 5 partsby weight, more preferably up to about 3 parts by weight.

The composition may, optionally, further comprise a curing promoter todecrease the gel time. Suitable curing promoters include transitionmetal salts and complexes such as cobalt naphthanate; and organic basessuch as N,N-dimethylaniline (DMA) and N,N-diethylaniline (DEA).Preferably, cobalt naphthanate and DMA are used in combination. Whenpresent, the promoter may be used in an amount of about 0.05 to about 3parts, per 100 parts total of the functionalized poly(arylene ether),the alkenyl aromatic monomer, and the acryloyl monomer.

The composition may further comprise one or more fillers, includingparticulate fillers and fibrous fillers. Examples of such fillers wellknown to the art include those described in “Plastic Additives Handbook,4^(th) Edition” R. Gachter and H. Muller (eds.), P. P. Klemchuck (assoc.ed.) Hansen Publishers, New York 1993. A particulate filler is hereindefined as a filler having an average aspect ratio less than about 5:1.Non-limiting examples of fillers include silica powder, such as fusedsilica and crystalline silica; boron-nitride powder and boron-silicatepowders for obtaining cured products having low dielectric constant andlow dielectric loss tangent; the above-mentioned powder as well asalumina, and magnesium oxide (or magnesia) for high temperatureconductivity; and fillers, such as wollastonite includingsurface-treated wollastonite, calcium sulfate (as its anhydride,dihydrate or trihydrate), calcium carbonate including chalk, limestone,marble and synthetic, precipitated calcium carbonates, generally in theform of a ground particulate which often comprises 98+% CaCO₃ with theremainder being other inorganics such as magnesium carbonate, ironoxide, and alumino-silicates; surface-treated calcium carbonates; talc,including fibrous, modular, needle shaped, and lamellar talc; glassspheres, both hollow and solid, and surface-treated glass spherestypically having coupling agents such as silane coupling agents and/orcontaining a conductive coating; and kaolin, including hard, soft,calcined kaolin, and kaolin comprising various coatings known to the artto facilitate the dispersion in and compatibility with the thermosetresin; mica, including metallized mica and mica surface treated withaminosilanes or acryloylsilanes coatings to impart good physicals tocompounded blends; fedspar and nepheline syenite; silicate spheres; fluedust; cenospheres; fillite; aluminosilicate (atmospheres), includingsilanized and metallized aluminosilicate; natural silica sand; quartz;quartzite; perlite; Tripoli; diatomaceous earth; synthetic silica,including those with various silane coatings, and the like.

Preferred particulate fillers include calcium carbonates having anaverage particle size of about 1 to about 10 micrometers. Within thisrange, the average particle size may be at least about 2 micrometers, orat least about 3 micrometers. Also within this range, the averageparticle size may be up to about 8 micrometers, or up to about 7micrometers.

Fibrous fillers include short inorganic fibers, including processedmineral fibers such as those derived from blends comprising at least oneof aluminum silicates, aluminum oxides, magnesium oxides, and calciumsulfate hemihydrate. Also included among fibrous fillers are singlecrystal fibers or “whiskers” including silicon carbide, alumina, boroncarbide, carbon, iron, nickel, copper. Also included among fibrousfillers are glass fibers, including textile glass fibers such as E, A,C, ECR, R, S, D, and NE glasses and quartz.

Preferred fibrous fillers include glass fibers having a diameter ofabout 5 to about 25 micrometers and a length before compounding of about0.5 to about 4 centimeters.

Many other suitable fillers are described in U.S. Published ApplicationNo. 2001/0053820 A1 to Yeager et al.

When present, the particulate filler may be used in an amount of about 5to about 80 weight percent, based on the total weight of thecomposition. Within this range, it may be preferred to us a particulatefiller amount of at least about 10 weight percent, more preferably atleast about 20 weight percent, yet more preferably at least about 30weight percent, still more preferably at least about 40 weight percent.Also within this range, it may be preferred to use a particulate filleramount of up to about 70 weight percent, more preferably up to about 60weight percent.

When present, the fibrous filler may be used in an amount of about 2 toabout 80 weight percent, based on the total weight of the composition.Within this range, it may be preferred to us a fibrous filler amount ofat least about 5 weight percent, more preferably at least about 10weight percent, yet more preferably at least about 15 weight percent.Also within this range, it may be preferred to use a fibrous filleramount of up to about 60 weight percent, more preferably up to about 40weight percent, still more preferably up to about 30 weight percent.

These aforementioned fillers may be added to the thermosetting resinwithout any treatment, or after surface treatment, generally with anadhesion promoter.

The formulation may also contain adhesion promoters to improve adhesionof the thermosetting resin to the filler or to an external coating orsubstrate. Also possible is treatment of the aforementioned inorganicfillers with adhesion promoter to improve adhesion. Adhesion promotersinclude chromium complexes, silanes, titanates, zirco-aluminates,propylene maleic anhydride copolymers, reactive cellulose esters and thelike. Chromium complexes include those sold by DuPont under thetradename VOLAN®. Silanes include molecules having the general structure(RO)_((4-n))SiY_(n) wherein n=1–3, R is an alkyl or aryl group and Y isa reactive functional group which can enable formation of a bond with apolymer molecule. Particularly useful examples of coupling agents arethose having the structure (RO)₃SiY. Typical examples includevinyl-triethoxysilane, vinyl tris(2-methoxy)silane,γ-methacryloxypropyltrimethoxy silane, γ-aminopropyltriethoxysilane,γ-glycidoxypropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane.Titanates include those developed by S. J. Monte et al. in Ann. Chem.Tech Conf. SPI (1980), Ann. Tech Conf. Reinforced Plastics and Compositeinst. SPI 1979, Section 16E, New Orleans; and S. J. Monte, Mod. PlasticsInt. 14(1984) 6 pg. 2. Zirco-aluminates include those described by L. B.Cohen in Plastics Engineering 39 (1983) 11, pg. 29. The adhesionpromoter may be included in the thermosetting resin itself, or coatedonto any of the fillers described above to improve adhesion between thefiller and the thermosetting resin. For example such promoters may beused to coat a silicate fiber or filler to improve adhesion of the resinmatrix.

In a preferred embodiment, the filler comprises calcium carbonate. Inanother preferred embodiment, the filler comprises glass fibers. In ahighly preferred embodiment, the filler comprises both calcium carbonateand glass fibers.

The composition may, optionally, further comprising an additive selectedfrom flame retardants, mold release agents and other lubricants,antioxidants, thermal stabilizers, ultraviolet stabilizers, pigments,dyes, colorants, anti-static agents, conductive agents, curingpromoters, and the like, and combinations comprising at least one of theforegoing additives. Selection of particular additives and their amountsmay be performed by those skilled in the art.

The composition may be prepared by forming an intimate blend of thefunctionalized poly(arylene ether), the alkenyl aromatic monomer, theacryloyl monomer, and the polymeric additive. When the functionalizedpoly(arylene ether) is a capped poly(arylene ether), the composition maybe prepared directly from an uncapped poly(arylene ether) by dissolvingthe uncapped poly(arylene ether) in a portion of the alkenyl aromaticmonomer, adding a capping agent form the capped poly(arylene ether) inthe presence of the alkenyl aromatic monomer, and adding the acryloylmonomer, the polymeric additive, and any other components to form thethermoset composition.

When a sol-gel is desired, the functionalized poly(arylene ether), thealkenyl aromatic monomer, the acryloyl monomer, and the polybutene aremixed together to form an intimate blend. The temperature of mixing toproduce a sol-gel may be at least 40° C., preferably at least 60° C.,and even more preferably at least 70° C. One of ordinary skill in theart can easily determine the time and the temperature of mixing requiredto form an intimate blend of the foregoing components. The blend isallowed to cool for a sufficient amount of time to form a sol-gel. Phaseseparation and sol-gel formation may occur by cooling the blend to atemperature below the sol-gel transition temperature at least about 1hour, preferably at least about 5 hours, and more preferably at leastabout 10 hours. The rate of cooling must be sufficient to allow thephase separation (sol-gel formation) to occur. Increasing the rate ofcooling may compromise phase separation and sol-gel formation.

There is no particular limitation on the method by which the compositionmay be cured. The composition may, for example, be cured thermally or byusing irradiation techniques, including UV irradiation and electron beamirradiation. When heat curing is used, the temperature selected may beabout 80° to about 300° C. Within this range, a temperature of at leastabout 120° C. may be preferred. Also within this range, a temperature upto about 240° C. may be preferred. The heating period may be about 30seconds to about 24 hours. Within this range, it may be preferred to usea heating time of at least about 1 minute, more preferably at leastabout 2 minutes. Also within this range, it may be preferred to use aheating time up to about 10 hours, more preferably about 5 hours, yetmore preferably up to about 3 hours. Such curing may be staged toproduce a partially cured and often tack-free resin, which then is fullycured by heating for longer periods or temperatures within theaforementioned ranges.

The composition exhibits highly desirable properties. For example insome embodiments the composition after molding may exhibit a shrinkageat least 10% less than the shrinkage exhibited by a correspondingcomposition without the polymeric additive. Shrinkage is determined bycomparing a dimension of a molded part with the corresponding dimensionof the mold. This comparison is performed at room temperature about 24hours after the sample is molded. The shrinkage is preferably at least20% less, more preferably at least 30% less, still more preferably atleast 40% less, even more preferably at least 50% less than that of theno-additive comparison.

The composition after molding in a Class A surface mold preferablyexhibits an orange peel value less than 40, more preferably less than35, still more preferably less than 30, yet more preferably less than25, even more preferably less than 20. These measurements are made usinga commercial technique called D-Sight in which incandescent light isreflected off the surface of a part. Surface roughness or waviness isseen as light and dark variations in reflected light intensity and arecorrelated with a numerical assessment of performance using softwarealgorithms. For these measurements, the D-Sight camera and light sourceare set at angle of 23 degrees below horizontal and the part placed at adistance of 50 inches from the base of the cameral/light source. Thepart itself is set at an angle of 10 degrees above horizontal facing theinspection system. Measurements are made on parts with gloss surfacesobtained by either painting the part with gloss black paint or wipingthe surface with highlighting oil. For measurements, the light levelreading is kept between 90 and 110.

The composition after molding in a Class A surface mold preferablyexhibits a waviness less than 300, more preferably less than 200, stillmore preferably less than 150, yet more preferably less than 120.

In one embodiment, the curable composition comprises: about 10 to about90 parts by weight functionalized poly(arylene ether); about 10 to about90 parts by weight alkenyl aromatic monomer; about 1.0 to about 50 partsby weight acryloyl monomer; and about 0.1 to about 30 parts by weightpolybutene based on 100 parts by weight total of the functionalizedpoly(arylene ether), the alkenyl aromatic monomer, the acryloyl monomer,and the polybutene, wherein the polybutene has a number averagemolecular weight of greater than or equal to about 300 atomic massunits.

Another embodiment is a curable composition comprising 10 to about 90parts by weight functionalized poly(arylene ether); about 10 to about 90parts by weight alkenyl aromatic monomer; about 1.0 to about 50 parts byweight acryloyl monomer; and about 0.1 to about 30 parts by weightpolybutene based on 100 parts by weight total of the functionalizedpoly(arylene ether), the alkenyl aromatic monomer, the acryloyl monomer,and the polybutene, wherein the polybutene has a number averagemolecular weight of greater than or equal to about 300 atomic massunits, and further comprising about 2.0 to about 80 weight percent ofglass filler based on the total weight of the composition.

Another embodiment is a method of forming a curable composition,comprising: blending a functionalized poly(arylene ether); an alkenylaromatic monomer; an acryloyl monomer; and a polybutene; wherein thepolybutene has a number average molecular weight of greater than orequal to about 300 atomic mass units.

Other embodiments include the reaction product obtained by curing any ofthe above curable compositions.

Still other embodiments include articles comprising any of the curedcompositions. Articles that may be fabricated from the compositioninclude, for example, acid bath containers, neutralization tanks,electrorefining tanks, water softener tanks, fuel tanks, filament-woundtanks, filament-wound tank linings, electrolytic cells, exhaust stacks,scrubbers, automotive exterior panels, automotive floor pans, automotiveair scoops, truck bed liners, drive shafts, drive shaft couplings,tractor parts, transverse leaf springs, crankcase heaters, heat shields,railroad tank cars, hopper car covers, boat hulls, submarine hulls, boatdecks, marine terminal fenders, aircraft components, propeller blades,missile components, rocket motor cases, wing sections, sucker rods,fuselage sections, wing skins, wing flairings, engine narcelles, cargodoors, aircraft stretch block and hammer forms, bridge beams, bridgedeckings, stair cases, railings, walkways, pipes, ducts, fan housings,tiles, building panels, scrubbing towers, flooring, expansion joints forbridges, injectable mortars for patch and repair of cracks in structuralconcrete, grouting for tile, machinery rails, metal dowels, bolts,posts, electrical encapsulants, electrical panels, printed circuitboards, electrical components, wire windings, seals forelectromechanical devices, battery cases, resistors, fuses, thermalcut-off devices, coatings for printed wiring boards, capacitors,transformers, electrically conductive components for antistaticapplications, tennis racquets, golf club shafts, fishing rods, skis, skipoles, bicycle parts, swimming pools, swimming pool slides, hot tubs,saunas, mixers, business machine housings, trays, dishwasher parts,refrigerator parts, furniture, garage doors, gratings, protective bodygear, luggage, optical waveguides, radomes, satellite dishes, signs,solar energy panels, telephone switchgear housings, transformer covers,insulation for rotating machines, commutators, core insulation, drytoner resins, bonding jigs, inspection fixtures, industrial metalforming dies, vacuum molding tools, and the like.

The composition is particularly useful for fabricating automotivecomponents such as, for example, automotive body panels.

The invention is further illustrated by the following non-limitingexamples.

EXAMPLES 1–7, COMPARATIVE EXAMPLE 1

Seven examples and one comparative example were prepared to demonstratethe effect of poly(vinyl ether) additives on shrinkage. The poly(aryleneether) was a methacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether)(“PPO-MAA”) having an intrinsic viscosity of 0.12 deciliters per gram at25° C. in chloroform. It was prepared as described in Example 1 ofInternational Patent Application WO 01/40354 A1. The crosslinker in allexamples was trimethylolpropane trimethacrylate (“TMPTMA”), obtainedfrom Sartomer. Styrene and t-butylperoxybenzoate were obtained fromAldrich Chemical Company. Calcium carbonate was obtained from OmyaCorporation as OMYACARB® 5. Glass fibers were obtained as choppedone-half inch fibers from Owens Corning Fiberglass Corporation.

An ethanol solution of a poly(ethyl vinyl ether) having a number averagemolecular weight (M_(n)) of approximately 22,000 atomic mass units (AMU)was obtained from Scientific Polymer Products. An ethanol solution of apoly(ethyl vinyl ether) having a number average molecular weight (M_(n))of approximately 1,000 AMU was obtained from Scientific PolymerProducts. An ethanol solution of a poly(isobutyl vinyl ether) having anumber average molecular weight (M_(n)) of approximately 15,000 AMU wasobtained from Scientific Polymer Products. Each poly(vinyl ether)solution was reduced to a neat poly(vinyl ether) resin by rotaryevaporation. The poly(vinyl ether) sample was weighed and dissolved inan equal weight of styrene. The resulting 50% poly(vinyl ether)/styrenesolution was combined with a 42.5 weight percent solution of PPO-MAA instyrene and trimethylolpropane trimethacrylate in the amounts (expressedin parts by weight, “pbw”) shown in Table 1, below. The solution becamefluid and apparently homogeneous after heating to approximately 50 to70° C. Zinc stearate and calcium carbonate (CaCO₃) were then added andthe mixture was stirred vigorously to form a pasty mixture. Thet-butylperoxybenzoate was added and the bulk molding compound was formedby blending the pasty mixture with one-half inch glass fibers in amixing bowl. The compositions were molded at 150° C. and 1,200 psi andthe shrinkage was measured by comparison of the width of the sample tothat of a the mold.

As shown, the shrinkage of blends containing poly(ethyl vinyl ether)and/or poly(isobutyl vinyl ether) (Exs. 1–7) was significantly lowerthan the control (C. Ex. 1), demonstrating the utility of poly(vinylether)s in reducing shrinkage of thermoset compositions comprisingpoly(arylene ether) resins. Example 4, with poly(isobutyl vinyl ether)exhibited slight expansion (negative shrinkage) of the molded part.

TABLE 1 Ex. 1 Ex. 2 Ex. 3 C. Ex. 1 Ex. 4 Ex. 5 Ex. 6 Ex. 7PPO-MAA/Styrene (42.5% wt./wt.) Solution (pbw) 85 85 85 85 85 85 85 85Trimethylolpropane Trimethacrylate (pbw) 20 20 20 20 20 20 20 20Poly(ethyl vinyl ether), M_(n) = 22,000 (pbw) 0 20 30 0 0 20 30 10Poly(ethyl vinyl ether), M_(n) = 1,000 (pbw) 0 0 0 0 0 0 0 10Poly(isobutyl vinyl ether), M_(n) = 15,200 (pbw) 0 0 0 0 20 0 0 0Styrene (pbw) 0 0 0 0 10 10 10 10 t-Butylperoxybenzoate (pbw) 2 2 0 2 22 0 2 Zinc Stearate (pbw) 3 3 0 3 3 3 0 3 Calcium Carbonate (6 micron)(pbw) 240 240 260 240 240 240 0 260 1/2″ Glass Fiber (pbw) 90 90 97.5 9090 90 0 97.5 Shrinkage (%) 0.183 0.047 0.014 0.183 −0.009 0.057 0.0050.06

EXAMPLES 8–24, COMPARATIVE EXAMPLES 2 AND 3

Twenty-five examples and two comparative examples were prepared, varyingprimarily in the type and amount of polymeric additive. Compositions andproperties are summarized in Table 2.

Two poly(arylene ether) types were used. The poly(arylene ether)designated “50/50-0.12 IV PPO-MAA/Styrene” in Table 2 was a 50 weightpercent solution in styrene of a methacrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of0.12 dL/g. The poly(arylene ether) designated “50/50-0.12 IVPPO-Psal/Styrene” was a 50 weight percent solution in styrene of apolysalicylate-capped poly(2,6-dimethyl-1,4-phenylene ether) having anintrinsic viscosity of 0.12 dL/g; this material was prepared using theprocedure from Example 3 of U.S. Pat. No. 4,760,118 to White et al.

Several polymeric additives were employed. The additive designated “CTBX162 Hycar” in Table 2 was a carboxy-terminated butadiene homopolymerhaving a carboxyl content acid number of 25, a solubility parameter(based on molar attraction constants) of 8.14, a number averagemolecular weight of 4,200 AMU, and a glass transition temperature of−77° C., obtained as HYCAR® 2000X162 CTB from Noveon Solutions. “CTBN1300X31 Hycar” was a carboxy-terminated butadiene (90%)/acrylonitrile(10%) copolymer having a carboxyl content acid number of 28, asolubility parameter of 8.14, a number average molecular weight of 3,800AMU, and a glass transition temperature of −66° C., obtained as HYCAR®1300X31 CTBN from Noveon Solutions. “VTBNX® 300X33 Hycar” was amethacrylate vinyl butadiene (82%)/acrylonitrile (18%) copolymer havingan acid number less than 5, a solubility parameter of 8.9, a numberaverage molecular weight of 3,600 AMU, and a glass transitiontemperature of −49° C., obtained as HYCAR® 1300X33 VTBNX from NoveonSolutions. “PMMA N700 AOC” was a poly(methyl methacrylate) homopolymerprovided as a 32 weight percent solution in styrene, obtained as N700from AOC Resins. “PS N715 AOC” was a polystyrene homopolymer provided asa 32 weight percent solution in styrene, obtained as N715 from AOCResins. “PVac LP40A UC” was a poly(vinyl acetate) copolymer provided asa 40 weight percent solution in styrene, obtained as LP40A from UnionCarbide (this product is currently sold by Dow Chemical). “PVac LP90 UC”was a poly(vinyl acetate) copolymer provided as a 40 weight percentsolution in styrene, obtained as LP90 from Union Carbide (now Dow).“PVac NeulonT UC” was a poly(vinyl acetate) copolymer provided as a 40weight percent solution in styrene, obtained as NEULON® T from UnionCarbide (now Dow). “SB Copoly XV-2314 AOC” was a styrene-butadienecopolymer provided as a 35 weight percent solution in styrene, obtainedas XV-2314 from AOC Resins.

The crosslinker in all examples was trimethylolpropane triacrylate(TMPTA).

An organic peroxide initiator was obtained as LUPEROX® P from Atofinaand used at 2 parts per hundred resin in all samples.

A calcium carbonate having an average particle size of 5 micrometers wasobtained from Omya Corporation and used at 56 weight percent in allsamples. Glass fibers having a length of 13 millimeters and a diameterof 17 micrometers were obtained as OCF-163D-17C from Owens Corning Fiberand used at 20 weight percent in all samples.

For each sample, the resin components were mixed thoroughly at about 60to 70° C. using a Cowles impellor to form a paste. After addinginitiator and inorganic fillers, glass fibers were compounded into thepaste using a low shear Hobart dough mixer.

Molding utilized a glass-A mold manufactured by Heyden Mold & Bench ofTailmadge, Ohio. For each composition, four plaques (approximately 650g, ⅛ inch thick by 12 inch square) were made by compression molding at1200 pounds per square inch (psi) for 2 minutes.

Part warp was measured as the maximum vertical deflection of a givencorner with the plaque resting on a flat reference surface.

For shrinkage evaluation, the part was clamped to a flat surface andplaque diagonals were measured. Shrinkage was calculated relative to thesize of the compression mold cavity.

Orange peel and waviness were measured with an LMI Technologies D-Sightanalyzer. These are non-contact measurements in which reflected light iscaptured by a video system and analyzed. The technique can be used toanalyze short-wave deviations (microns to about 1 centimeter; “orangepeel”) and long-wave deviations (about 1 centimeter to as large as thedimension of the sampled area; “waviness”) from a perfectly flatsurface. For a given data set, all measurements were made during thesame measurement session. Lower values of orange peel and roughness aremore desirable. Although there is not currently a standard definition ofClass A Surface, it is generally considered to include an orange peelvalue less than or equal to about 20 and a waviness value less than orequal to 120.

Cured phase behavior was determined as follows. All resin chemistrieswere separately formulated in the lab without inorganic filler or glassreinforcement. Drops of the resins without initiator were placed in thepolished well of a glass slide, covered, and inspected under amicroscope equipped with a METTLER® hot stage. Visual inspection wasused to assess miscibility, first at 150° C. and then again aftercooling to 25° C. In separate samples, initiator was added to the neatresins and they were molded into 3 mm thick plaques between two sheetsof polished metal plate using a Micromet Instruments Minipress(MP-2000). Assessments of uncured resin miscibility are denoted as “+”for miscible, “−” for immiscible. Cured resin phase behavior are denotedas “S” for single phase, “M” for multiphase. These assessments are basedon the presence or absence of discernable heterogeneities that, inuncured resins, are large enough to be observed under an opticalmicroscope, or, in cured samples, are large enough to scattersignificant visible light and render samples translucent or opaque.

The results in Table 2 show that Examples 8–24 with styrene-butadienecopolymer, polystyrene, poly(methyl methacrylate), poly(vinyl acetate),carboxy-terminated polybutadiene, or carboxy-terminatedpoly(butadiene-co-acrylonitrile), exhibited reduced shrinkage comparedto their respective controls (Comparative Example 2 and 3). Waviness wasalso reduced in most cases.

TABLE 2 C. Ex. 2 C. Ex. 3 Ex. 8 Ex. 9 Ex. 10 Base Resin Type 50/50 -0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IVPPO-MAA/Styrene PPO-Psal/Styrene PPO-MAA /Styrene PPO-MAA/StyrenePPO-MAA/Styrene Base Resin Amount (pbw) 74 74 60.7 63.8 58.4 AdditiveType — — SB Copoly XV- PS N715 AOC PMMA N700 2314 AOC AOC. AdditiveAmount (pbw) 0 0 28.6 25.0 31.3 Additional Styrene Amount 13.0 13.0 0 00 (pbw) Crosslinker Amount (pbw) 13.1 13.1 10.7 11.3 10.3 ResinMiscibility −/+ +/+ −/+ −/+ −/− 25° C./150° C. Cured Phase Behavior S MS M M Warp (mm) 1.2 8.7 5.4 2.7 3.2 Shrinkage (%) 0.22 0.28 0.20 0.200.18 Orange Peel 33 41 37 38 40 Waviness 1798 1788 2000 1870 1561Critical Strain (%) 0.52 0.39 — 0.53 0.52 Ex. 11 Ex. 12 Ex. 13 Ex. 14Ex. 15 Base Resin Type 50/50 - 0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IV50/50 - 0.12 IV 50/50 - 0.12 IV PPO-MAA/Styrene PPO-MAA/StyrenePPO-MAA/Styrene PPO-MAA/Styrene PPO-MAA/Styrene Base Resin Amount (pbw)63.8 63.8 63.8 66.5 66.5 Additive Type PVac LP40A UC PVac LP90 UC PVacNeulonT UC CTB 2000X162 CTBN 1300X31 Hycar Hycar Additive Amount (pbw)25.0 25.0 25.0 10.0 10.0 Additional Styrene Amount 0 0 0 11.8 11.8 (pbw)Crosslinker Amount (pbw) 11.3 11.3 11.3 11.7 11.7 Resin Miscibility −/−−/− −/− −/+ −/+ 25° C./150° C. Cured Phase Behaviour M M M S? S? Warp(mm) 2.9 1.8 1.4 1.3 0.9 Shrinkage (%) 0.17 0.18 0.18 0.13 0.13 OrangePeel 37 36 39 37 40 Waviness 1082 1406 1549 1569 1184 Critical Strain(%) 0.59 0.51 0.59 0.55 0.57 Ex. 16 Ex. 17 Ex. 18 Ex. 19 Ex. 20 BaseResin Type 50/50 - 0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IV 50/50 - 0.12IV 50/50 - 0.12 IV PPO-Psal/Styrene PPO-Psal/Styrene PPO-Psal/StyrenePPO-Psal/Styrene PPO-Psal/Styrene Base Resin Amount (pbw) 60.7 63.8 58.463.8 63.8 Additive Type SB Copoly XV- PS N715 AOC PMMA N700 PVac LP40AUC PVac LP90 UC 2314 AOC AOC Additive Amount (pbw) 28.6 25.0 31.3 25.025.0 Additional Styrene Amount 0 0 0 0 0 (pbw) Crosslinker Amount (pbw)10.7 11.3 10.3 11.3 11.3 Resin Miscibility +/+ +/+ −/− −/− −/− 25°C./150° C. Cured Phase Behaviour S M M M M Warp (mm) 4.1 2.9 1.4 1.5 1.9Shrinkage (%) 0.27 0.25 0.25 0.15 0.20 Orange Peel 52 40 38 33 46Waviness 1309 1295 753 691 1926 Critical Strain (%) 0.45 0.46 0.45 0.460.45 Ex. 21 Ex. 22 Ex. 23 Ex. 24 Base Resin Type 50/50 - 0.12 IV 50/50 -0.12 IV 50/50 - 0.12 IV 50/50 - 0.12 IV PPO-Psal/StyrenePPO-Psal/Styrene PPO-Psal/Styrene PPO-Psal/Styrene Base Resin Amount(pbw) 63.8 66.5 66.5 66.5 Additive Type PVac NeulonT UC CTB 2000X162CTBN 1300X31 VTBN 1300X33 Hycar Hycar Hycar Additive Amount (pbw) 25.010.0 10.0 10.0 Additional Styrene Amount 0 11.8 11.8 11.8 (pbw)Crosslinker Amount (pbw) 11.3 11.7 11.7 11.7 Resin Miscibility 25°C./150° C. −/− −/+ −/+ −/+ Cured Phase Behaviour M M M M Warp (mm) 2.31.7 2.0 7.0 Shrinkage (%) 0.16 0.15 0.16 0.29 Orange Peel 38 39 45 57Waviness 1025 1182 1607 2625 Critical Strain (%) 0.52 0.45 0.47 0.41

EXAMPLES 25–30

Six samples were prepared varying in crosslinker amount, and polymericadditive and amount. The base resin for all samples was a 50 weightpercent solution in styrene of a methacrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of0.12 dL/g.

The crosslinker was trimethylolpropane triacrylate (TMPTA) ortrimethylolpropane trimethacrylate (TMPTMA). The initiator was t-butylperoxy-2-ethylhexanoate, obtained as LUPEROX® 26 from Atofina Chemicals.

Three different polymeric additives were used. The additive designated“PEB Kraton L1203” in Table 3 was a monohydroxy-terminatedpoly(ethylene-butylene) having a hydroxyl equivalent molecular weight of4,200 AMU, an approximate hydroxyl functionality of 0.9, and a specificgravity of 0.88 g/cc, obtained as KRATON® L1203 from Kraton Polymers.“PB Lithene N4-9000” was a liquid polybutadiene having a number averagemolecular weight of 9,000, 10–20% 1,2 vinyl microstructure, 50–60%trans-1,4 and 25–35% cis-1,4 structure, obtained as N4-9000 fromRevertex Chemicals Limited (Hartlepool, UK) “CTB Hycar 2000X162” was acarboxy-terminated butadiene homopolymer having a carboxyl content acidnumber of 25, a solubility parameter (based on molar attractionconstants) of 8.14, a number average molecular weight of 4,200 AMU, anda glass transition temperature of −77° C., obtained as HYCAR® 2000X162CTB from Noveon Solutions.

Each sample was prepared as a 3 kilogram batch containing 25 weightpercent resin, 54 weight percent calcium carbonate, 20 weight percentglass fibers, and 1 weight percent of the mold release agent zincstearate. Components amount in Table 3 are expressed in grams andreflect contributions to a 3 kg batch.

Samples molded at 120° C. and 1,200 psi for 2 minutes. Orange peel wasmeasured as described above. Compositions and properties are summarizedin Table 3. The results show reduced orange peel values relative tocontrol samples represented by Control Examples 4 and 5, below.

TABLE 3 Ex. 25 Ex. 26 Ex. 27 Ex. 28 Ex. 29 Ex. 30 Base Resin Amount(pbw) 612 576 574 540 574 540 Crosslinker Type TMPTA TMPTMA TMPTA TMPTMATMPTA TMPTMA Crosslinker Amount (pbw) 108 144 101 135 101 135 AdditiveType PEB Kraton PEB Kraton PB Lithene N4- PB Lithene N4- CTB Hycar X162CTB Hycar X162 L1203 L1203 9000 9000 Additive Amount (pbw) 30 30 75 7575 75 Initiator Amount (pbw) 15 15 15 15 15 15 Mold Release Amount 30 3030 30 30 30 (pbw) Carbonate Amount (pbw) 1620 1620 1620 1620 1620 1620Glass Fiber Amount (pbw) 600 600 600 600 600 600 Orange Peel 24.2 24.031.9 28.4 31.8 34.4

EXAMPLES 31–36, COMPARATIVE EXAMPLE 4

Nine compositions were prepared, varying in the amount of polybutadieneand poly(ethylene-butylene) additives. The base resin for all sampleswas a 50 weight percent solution in styrene of a methacrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of0.12 dL/g. The crosslinker for all samples was trimethylolpropanetrimethacrylate. A polybutadiene having a number average molecularweight of 8,000, and a vinyl content of 28% was obtained as RICON® 134from Sartomer. A monohydroxy-terminated poly(ethylene-butylene)copolymer having a hydroxyl equivalent weight of 4,200 and 0.9 hydroxylfunctionality was obtained as KRATON® L1203 from Kraton Polymers. Allsamples were based on 25% total resin, 54% calcium carbonate, 1% zincstearate, and 20% 13 millimeter glass fibers.

Molding was performed at 150° C. and 1,200 psi. Shrinkage, orange peel,and waviness were measured for each sample.

The results, presented in Table 4, show that either polybutadiene orpoly(ethylene-butene) alone reduces shrinkage and, in most cases, orangepeel and waviness. The results further show that the combination ofpolybutadiene and poly(ethylene-butylene), each at 5 weight percent, isparticularly effective to reduce shrinkage, orange peel, and waviness.

TABLE 4 C. Ex. 4 Ex. 31 Ex. 32 Ex. 33 Ex. 34 Ex. 35 Ex. 36 Base resin(pbw) 80 80 80 80 80 80 80 Trimethylopropane trimethacrylate (pbw) 20 2020 20 20 20 20 polybutadiene (pbw) — 5 10 — 13 2.5 5.0poly(ethylene-butylene) (pbw) — — — 2.5 5.0 2.5 5.0 Shrinkage (%) 0.240.23 0.17 0.17 0.14 0.17 0.13 Orange Peel 45 47 40 40 40 43 32 Waviness1700 1800 1300 1500 910 1450 760

EXAMPLE 37, COMPARATIVE EXAMPLE 5

Two samples were prepared with and without 110 weight percent of a 50:50weight/weight mixture of polybutadiene and poly(ethylene-butylene).Components were the same as those described above for Examples 38–43.

Molding was performed at 150° C. and 1,200 psi. Shrinkage, orange peel,and waviness values represent averages for two samples.

Compositions and properties are presented in Table 5. The results showthat the combination of polybutadiene and poly(ethylene-butylene) isparticularly effective at reducing shrinkage (to the point of causingslight expansion in Ex. 44), orange peel, and waviness.

TABLE 5 C. Ex. 5 Ex. 37 50/50 0.12 IV PPO-MAA/styrene (pbw) 80 80Trimethylolpropane trimethacrylate (pbw) 20 20 Polybutadiene (pbw) — 5Poly(ethylene-butylene) (pbw) — 5 Shrinkage (%) 0.095 −0.016 Orange Peel45 26 to 35 Waviness 1670 135 to 330

EXAMPLES 38–55

Eighteen samples were prepared varying in the type and amount ofcrosslinker, the type and amount of polymeric additive, the type andamount of initiator, and the molding temperature.

The base resin for all examples was a methacrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of0.12 dL/g. It was used in the form of a 50 weight percent solution instyrene. The initiator t-butyl peroxy-2-ethylhexanoate was obtained asLUPEROX® 26 from Atofina Chemicals. The initiator t-butyl perbenzoatewas obtained as LUPEROX® P from Atofina Chemicals. The crosslinker waseither trimethylolpropane triacrylate (TMPTA) or trimethylolpropanetrimethacrylate (TMPTMA).

Five different polymeric additives were employed. A dihydroxy-terminatedpoly(ethylene-butylene) having a weight average molecular weight of1,700 AMU was obtained as KRATON® L2203 from Kraton Polymers. Amonohydroxy-terminated poly(ethylene-butylene) having a weight averagemolecular weight of 4,200 AMU was obtained as KRATON® L1203 from KratonPolymers. A polybutadiene having a number average molecular weight of5,000 AMU and 10–20% vinyl content was obtained as Lithene N4-5000 fromRevertex Chemicals Limited, Hartlepool, UK. Anethylene-propylene-dicyclopentadiene terpolymer having anethylene:propylene weight ratio of 48/52, 9.5 weight percent diene, aviscosity average molecular weight of 7,000 AMU, and a weight averagemolecular weight of 40,000 AMU was obtained as TRILENE® 65 from UniroyalChemical. An ethylene-propylene-ethylidene norbornene terpolymer havingan ethylene:propylene weight ratio of 45/55, 9.5% diene by weight, aviscosity average molecular weight of 7,500 AMU and a weight averagemolecular weight of 40,000 AMU was obtained as TRILENE® 67 from UniroyalChemical.

All amounts in Table 6 below are grams per 3 kilogram batch. All samplescontained 25 weight percent resin, 54 weight percent calcium carbonate,20 weight percent glass fibers (OCF 163D-17C from Owens Corning), and 1weight percent zinc stearate. The following are the same for allsamples: initiator amount=15 g; zinc strearate amount=30 g; calciumcarbonate amount=1620 g; molding time=2 minutes; molding pressure=1,200psi.

The results, presented in Table 6, show reduced orange peel and wavinessfor the samples containing polymeric additives versus samples withoutthem (see Comparative Examples 4 and 5, above).

TABLE 6 Ex. 38 Ex. 39 Ex. 40 Ex. 41 Ex. 42 Ex. 43 Ex. 44 Resin Amt (pbw)625 618 612 625 618 612 625 Crosslinker type TMPTA TMPTA TMPTA TMPTATMPTA TMPTA TMPTA Crosslinker Amt 110 109 108 110 109 108 110 (pbw)Additive Type KRATON ® KRATON ® KRATON ® KRATON ® KRATON ® KRATON ®KRATON ® L2203 L2203 L2203 L2203 L2203 L2203 L1230 Additive Amt (pbw) 1523 30 15 23 30 15 Initiator Type LUPEROX ® LUPEROX ® LUPEROX ® LUPEROX ®P LUPEROX ® P LUPEROX ® P LUPEROX ® 26 26 26 26 MoldingTemp(° C.) 120120 120 150 150 150 120 Orange Peel 24.2 24.0 31.9 28.4 31.8 34.4 33.9Waviness 776 978 1168 1431 685 1092 1075 Ex. 45 Ex. 46 Ex. 47 Ex. 48 Ex.49 Ex. 50 Ex. 51 Resin Amt (pbw) 618 612 625 618 612 574 574 Crosslinkertype TMPTA TMPTA TMPTA TMPTA TMPTA TMPTA TMPTA Crosslinker Amt 109 108110 109 108 101 101 (pbw) Additive Type KRATON ® KRATON ® KRATON ®KRATON ® KRATON ® Lithene N4- TRILENE ®65 L1230 L1230 L1230 L1230 L12305000 Additive Amt (pbw) 23 30 15 23 30 75 75 Initiator Type LUPEROX ®LUPEROX ® LUPEROX ® P LUPEROX ® P LUPEROX ® P LUPEROX ® P LUPEROX ® P 2626 Moldin Temp (° C.) 120 120 150 150 150 150 150 Orange Peel 29.6 28.037.5 35.5 34.4 25.0 27.3 Waviness 1194 904 1519 1590 1457 569 600 Ex. 52Ex. 53 Ex. 54 Ex. 55 Resin Amt (pbw) 574 576 540 612 Crosslinker typeTMPTA TMPTMA TMPTMA TMPTMA Crosslinker Amt 101 144 180 108 (pbw)Additive Type TRILENE ® 67 KRATON ® KRATON ® KRATON ® L1203 L1203 L1203Additive Amt (pbw) 75 30 30 30 Initiator Type LUPEROX ® P LUPEROX ® PLUPEROX ® P LUPEROX ® P Molding Temp(° C.) 150 150 150 150 Orange Peel24.3 26.5 28.3 31.3 Waviness 1000 884 902 1044

EXAMPLES 56–64, COMPARATIVE EXAMPLE 6

Ten samples were prepared varying in the type and amount of crosslinker,the type and amount of polymeric additive, the type and amount ofinitiator, and the molding temperature. The base resin for all sampleswas a methacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether) havingan intrinsic viscosity of 0.12 dL/g, which was used as a 50 weightpercent solution in styrene.

Initiators and polymeric additives are described above, except forRICON® 134, which is a polybutadiene having a number average molecularweight of 8,000 AMU and 28% vinyl content, obtained from Sartomer.

All formulations were prepared on a 1.5 kilogram scale, consisting of 25weight percent resin, 54 weight percent calcium carbonate, 20 weightpercent glass fibers, and a 1 weight percent zinc stearate. Componentamounts in Table 7 are in grams per 1.5 kilogram batch. The follow areconstants in these samples: initiator amount=7.5 g, zinc stearateamount=15 g; calcium carbonate amount=810 g; glass fiber amount=300 g;molding time=2 minutes; molding pressure=1,200 psi.

The results, presented in Table 7, show that the carboxy-terminatedbutadiene was effective at improving surface quality when molded atlower temp (120° C. vs. 150° C.)— the improvement is significantrelative to a control (C. Ex. 6). The CTB appeared to be more highlyphase separated at the lower temp enabling low profile additivemorphology and performance. Both polybutadiene (RICON® 134) and PEB(KRATON® L1203) by themselves offered improvements relative to control(C. Ex. 6), but there was a synergistic improvement over either alonewhen these two were combined.

TABLE 7 Ex. 56 Ex. 57 C. Ex. 6 Ex. 58 Ex. 59 Ex. 60 Ex. 61 Ex. 62 ResinAmt 287 287 300 285 270 293 285 285 (pbw) Crosslinker TMPTA TMPTA TMPTMATMPTMA TMPTMA TMPTMA TMPTMA TMPTMA Type Crosslinker 51 51 75 71 68 73 7171 Amt (pbw) Additive I CTB CTB — RICON ® RICON ® KRATON ® KRATON ®KRATON ® Type HYCAR ® HYCAR ® 134 134 1203 1203 1203 X162 X162 AdditiveI 38 38 — 19 38 9 19 9 Amt (pbw) Additive II — — — — — — — RICON ® Type134 Additive II 0 0 0 0 0 0 0 9 Amt (pbw) Initiator Type LUPEROX ®LUPEROX ® LUPEROX ® LUPEROX ® LUPEROX ® LUPEROX ® LUPEROX ® LUPEROX ® 26P P P P P P P Molding Temp 120 150 150 150 150 150 150 150 ° C.Shrinkage 0.13 0.13 0.24 0.23 0.17 0.17 0.14 0.17 Orange Peel 30 57 4547 40 40 40 43 Waviness 505 1710 1670 1805 1300 1520 910 1440 Ex. 63 Ex.64 Resin Amt (pbw) 270 287 Xlinker Type TMPTMA TMPTMA Xlinker Amt (pbw)68 51 Additive I Type KRATON ® KRATON ® 1203 1203 Additive I Amt (pbw)19 19 Additive II Type RICON ® RICON ® 134 134 Additive II Amt (pbw) 1919 Initiator Type LUPEROX ® LUPEROX ® P P Molding Temp ° C. 150 150Shrinkage 0.13 0.10 Orange Peel 32 33 Waviness 760 440

EXAMPLES 65–72, COMPARATIVE EXAMPLE 7

These experiments show that the polymeric additives are also effectivefor reducing the painting defect known as “paint popping”. Fourcompositions were prepared varying in base resin intrinsic viscosity,polymeric additive type, and polymeric additive amount. The base resinswere a methacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether) resinshaving an intrinsic viscosities of 0.12, and an acrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) resins having an intrinsicviscosities of 0.30 dL/g. The polymeric additives were acarboxy-terminated polybutadiene (“CTB”) obtained as HYCAR® 2000X162 CTBfrom Noveon Solutions, and a 32 weight percent solution of polystyrene(“PS”) in styrene obtained as N715 from AOC Resins. All formulationsconsisted of 25 weight percent resin, 54 weight percent calciumcarbonate, 20 weight percent glass fibers, and 1 weight percent zincstearate. Initiator was added at 2 parts per 100 parts by weight of thebase resin. t-Butyl perbenzoate, obtained as LUPEROX® P from AtofinaChemicals, was used for 150° C. cures. t-Butyl peroxy-2-ethylhexanoate,obtained as LUPEROX® 26 from Atofina Chemicals, was used for 120° C.cures. The formulated resins contained 15 weight percent of thecrosslinker trimethylolpropane trimethacrylate. Component amounts aregiven in Table 8.

The two polymeric additives were separately blended with base resin,initiator, and crosslinker. To these mixtures, the calcium carbonate andglass were added along with the mold release agent. The resultantcomposite resins were divided into appropriate weight charges and eachwere compression molded into a 12×12 inch plaque at conditions oftemperature and pressure known to result in complete cure of thethermoset. A total of three plaques were prepared for each composition.As a further control measure, the entire process was repeated on asecond day, generating a second “replicate” set of three plaques foreach composition.

Each of the molded plaques was subjected to an aggressive edge sandingprotocol to produce rounded edges. Using an orbital sander, each edgewas then sanded, using a circular motion, to obtain a rounded profile.Typically between 5 and 10 sanding passes at various angles wererequired to obtain a uniform rounded edge. After sanding, all sampleswere sent to an automotive painting company to be primed and paintedunder conditions identical to those experienced by automotive parts madefrom commercial thermoset composites. The priming/painting protocolfollowed the standard adopted by a consortium of automotive companiesand their thermoset part suppliers (molding and priming companies.) Allplaques were then returned for measurement of edge pop defects.

The plaques were clamped to a computer-controlled scanning sled thatpermitted the precise linear positioning of the plaque under a videocamera. The scanning sled was programmed to travel 2 inches, pause for2.5 seconds, and proceed to the next 2-inch segment of the plaque. Thesled was programmed to perform this scan sequence 6 times in order tocover the entire 12-inch length of the plaque. sides. The procedure wasrepeated 4 times in order to analyze all edges of the plaque.

Proper illumination orientation was critical in order to achievesufficient contrast of the edge pops. A dual chromed gooseneck fiberoptic light source was used to provide an angled source of lightapproximately 30° below the top of the plaque. Each gooseneck lightsource was positioned on either side of the plaque in order to minimizeshadows and to illuminate edge pops on either side of the curved edge ofthe plaque side being analyzed.

The magnification was optimized in order to resolve the smallest typicalobservable edge pop (approximately 6 mils), permit a manageable numberof areas for analysis from each side (6), and retain good contrastbetween the edge pops and the smooth painted surface. The scanning sledwas positioned on a macro-stand that had a video camera with a 50 mmmacro lens attached. The video camera was interfaced to a PC-based imageanalysis system.

The image analysis system was coordinated with the computer-controlledscanning sled such that the image analyzer would automatically digitizethe image and store it to the hard drive and repeat this process 6 timesin order to store 6 images from each side of a plaque. A separateroutine was written which first enhanced the contrast in the image ofthe edge and transformed the gray level image into a binary image byselecting the characteristic gray level range of the edge pops. Once thebinary image was created, the image analysis program determined the edgepop defect size for every defect detected. A Microsoft EXCEL® macro waswritten to determine the average edge pop defect diameter, maximumdiameter, and number density for each plaque edge.

Continuous data on the individual plaque edges (four twelve-inch edgesper plaque) of each separate formulation were generated for thefollowing measurements: paint pop number per area (counts per squarecentimeter of sanded edge), average paint pop diameter (millimeters),and maximum paint pop diameter (millimeters). The normality of thedistributions of the paint pop number data allowed calculation of apooled average for each formulation and its replicate. For eachmeasurement type, the average and standard deviations are thereforebased on 24 measurements, corresponding to 2 batches times 3plaques/batch times 4 edges/plaque. For example, for a givenformulation, Maximum Pop Diameter and its standard deviation areobtained by measuring the maximum pop diameter for each of the 24 totaledges for that formulation, then calculating an average and standarddeviation based on the population of 24 maximum pop diameters. Table 8lists the statistics of the individual formulations.

These experiments demonstrate that the polymeric additives can reduceedge popping defects.

TABLE 8 C. Ex. 7 Ex. 65 Ex. 66 Ex. 67 Base Resin Capping Groupmethacrylate methacrylate methacrylate acrylate Base Resin IntrinsicViscosity (dL/g) 0.12 0.12 0.12 0.30 Base Resin Amount (pbw) 626.6 576.5501.4 501.4 Crosslinker amount (pbw) 113.3 104.2 90.61 90.61 PolymericAdditive Type (none) CTB PS PS Polymeric Additive Amount (pbw) 0 60.38150.9 150.9 Initiator Type LUPEROX ® P LUPEROX ® 26 LUPEROX ® PLUPEROX ® P Initiator Amount (pbw) 15.1 13.89 12.08 12.08 Zinc StearateAmount (pbw) 29.89 29.89 29.89 29.89 Calcium Carbonate Amount (pbw)1630.1 1630.1 1630.1 1630.1 Glass Fiber Amount (pbw) 603.75 603.75603.75 603.75 Average Pop Number (counts/cm²) 3.16 1.74 1.53 1.41standard deviation (counts/cm²) 1.65 0.98 0.84 0.70 Average Pop Diameter(mm) 0.48 0.36 0.47 0.35 standard deviation (mm) 0.09 0.05 0.12 0.00Maximum Pop Diameter (mm) 1.33 0.72 1.05 0.68 standard deviation (mm)0.50 0.19 0.40 0.20

EXAMPLE 73, COMPARATIVE EXAMPLE 8

Two compositions were prepared to illustrate the effect of a poly(vinylester) compound on shrinkage. The functionalized poly(arylene ether) wasprovided as a 35 weight percent solution in styrene of amethacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether) having anintrinsic viscosity of 0.12 dL/g. A poly(vinyl laurate) having a numberaverage molecular weight of 110,000 AMU was obtained from ScientificPolymer Products. Shrinkage was measured as described in Examples 1–7.Compositions and shrinkage values are provided in Table 9. Note that theratios of resin to calcium carbonate and (resin+calcium carbonate) toglass fiber are the same for both samples. The results show thataddition of the poly(vinyl ester) reduced the shrinkage of thecomposition.

TABLE 9 C. Ex. 8 Ex. 73 COMPOSITION PPO-MAA/styrene solution (pbw) 85 85Trimethylolpropane trimethacrylate (pbw) 20 20 Poly(vinyl laurate) (pbw)0 20 Zinc Stearate (pbw) 3 3 t-Butylperoxybenzoate (pbw) 2 2 Calciumcarbonate (pbw) 220 240 Glass fiber (pbw) 83 85 PROPERTIES Shrinkage (%)0.18 0.011

EXAMPLES 74 TO 79

Six compositions varying in poly(vinyl ester) type were prepared. Eachsample contained 80 parts by weight of at 35% solution in styrene ofmethacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether) having anintrinsic viscosity of 0.12 dL/g, 20 parts by weight oftrimethylolpropane trimethacrylate, 10 parts by weight of the poly(vinylalkanoate), and 2 parts by weight of t-butylperoxybenzoate initiator.The poly(vinyl esters)s were poly(vinyl propionate), poly(vinylpivalate), poly(vinyl nonanate), poly(vinyl butyrate), poly(vinylneodecanoate), and poly(vinyl neononanate). The blends were prepared bymixing the capped-PPE, the poly(vinyl ester), and the trimethylolpropanetrimethacrylate at about 50–80° C. The resulting solutions were cooledto about 40–60° C. before addition of the initiator. The compositionswere cured at 150° C. All blends showed phase separation as indicated bythe opaque white appearance of the cured discs. This opaque appearanceindicates phase separation, which is an important indication ofcavitation in the cured specimens. Poly(vinyl propionate) and poly(vinylpivalate) produced the highest level of whitening.

EXAMPLES 80 TO 82, COMPARATIVE EXAMPLE 9

Four compositions were prepared to illustrate the effect of polysiloxanecompounds on shrinkage. The functionalized poly(arylene ether) wasprovided as a 35 weight percent solution in styrene of amethacrylate-capped poly(2,6-dimethyl-1,4-phenylene ether) having anintrinsic viscosity of 0.12 dL/g. A vinyl-terminatedpolydimethylsiloxane (i.e., a polydimethylsiloxane have a vinyl group oneach end) was obtained from Aldrich Chemical Company. Apolydimethylsiloxane-co-methyl-3-hydroxypropylsiloxane-graft-poly(ethylene-propylene)glycol was obtained from Aldrich Chemical Company. A hydroxy-terminatedpolydimethylsiloxane was obtained from Aldrich Chemical Company.Shrinkage was measured as described in Examples 1–7. Compositions andshrinkage values are provided in Table 10. The results show thataddition of the vinyl-terminated and dihydroxy-terminatedpolydimethylsiloxanes reduced the shrinkage of the composition.

TABLE 10 C. Ex. 9 Ex. 80 Ex. 81 Ex. 82 COMPOSITION PPO-MAA/styrenesolution (pbw) 85 85 85 85 Trimethylolpropane 20 20 20 20trimethacrylate (pbw) Vinyl-terminated 0 10 0 0 polydimethylsiloxane(pbw) Polydimethylsiloxane-co-methyl-3- 0 0 10 0hydroxypropylsiloxane-graft-poly (ethylene-propylene) glycol (pbw)Hydroxy-terminated 0 0 0 10 polydimethylsiloxane (pbw) Zinc Stearate(pbw) 3 3 3 3 t-Butylperoxybenzoate (pbw) 2 2 2 2 Calcium carbonate(pbw) 220 240 240 240 Glass fibers (pbw) 83 85 88 88 PROPERTIESShrinkage (%) 0.18 0.052 0.21 0.072

EXAMPLES 83 TO 92, COMPARATIVE EXAMPLES 10–12

Thirteen compositions were prepared varying in amounts of threepolymeric additives, and amounts of magnesium oxide, titanium dioxide,and calcium carbonate. Components are as described above, except for amaleic anhydride-functionalized polybutadiene having a number averagemolecular weight of 5,300 AMU and 18–33% 1,2-vinyl content, obtained asRICON® 131MA5 from Sartomer; a calcium carbonate having a particle sizeof 6 micrometers, obtained as CamelFil 6μ; and chopped one inch glassroving, obtained as PPG 5530 from PPG.

Batches of filled resin, 18 kg in size, were compounded using a Cowlesblade mixer in five-gallon pails by first heating the base PPO instyrene resin and crosslinker to 35° C. Calcium carbonate, preheated ina cement mixer with a kerosene forced-air heater to between 55° C. and65° C., was then combined with titanium oxide and zinc stearate andadded to form a paste. Polymeric additives were incorporated next, andthen, immediately before coating, the magnesium oxide and initiator wereadded.

Sheet molding compound (SMC) was produced from the compositions using a60 cm wide line. The line included various elements to add heat to theprocess. The aluminum plates beneath both doctor boxes were heated withcirculating water to bring the surface temperatures of the first andsecond boxes to 35° C. and 45° C., respectively. Hot water at 90° C. wascirculated through the compaction rollers, and the entire compactionarea was enclosed and maintained at 40° C. with the aid of a warm airconvection heater. The doctor blades on both resin boxes were set with a0.098 inch gap. Pressure on the compactor roles was set at 10 psi at theentrance, 20 psi for rolls 2 through 8, and at 40 psi on the exitroller.

Sheet molding compounds were compression molded using a Class-A moldmanufactured by ToolPlas of Windsor, Ontario, Canada. Stacks of four 15centimeter SMC squares weighing 650 g each were formed into 3 mm thickby 30 cm square plaques by compression molding at 150° C. and 1200 psifor 2 minutes. Thus, the typical charge coverage on the molding area was25%, but in limited studies complete coverage was explored.

For shrinkage measurements, each molded plaque was clamped flat into aspecially made jig and the deviation from a calibrated part width wasmeasured at two points on orthogonal sides. Each plaque was rotated 90degrees and remeasured to minimize part orientation effects. Shrinkagewas calculated relative to the zero calibrations established by themanufacturer of the device. Three plaques were tested for eachformulation and the average and standard deviation for each compositionare provided in Table 11. At least a four-fold reduction in shrinkagewas obtained when the polymeric additive combination of apoly(ethylene-butene) and a polybutadiene was employed (Exs. 83–92 vs.C. Exs. 10–12).

Waviness and orange peel were measured as described above, usingsurfaces painted gloss black. Examples 83–92 comprising polymericadditives exhibited substantially lower waviness and orange peel valuesthan Comparative Examples 10–12 lacking polymeric additives.

TABLE 11 C. Ex. 10 C. Ex. 11 C. Ex. 12 Ex. 83 Ex. 84 Ex. 85 Ex. 86 Ex.87 Ex. 88 COMPOSITION 50% PPO-MMA/styrene solution (pbw) 80.0 80.0 80.072.0 72.0 72.0 72.0 72.0 72.0 Trimethylolpropane trimethacrylate 20.020.0 20.0 18.0 18.0 18.0 18.0 18.0 18.0 (pbw) KRATON L1203 (pbw) 0 0 0 55 5 5 5 5 RICON 134 (pbw) 0 0 0 5 5 5 5 5 5 RICON 131MA (pbw) 0 0 0 0 00 0 0 0 t-Butylperoxybenzoate (pbw) 2 2 2 2 2 2 2 2 2 Zinc Sterate (pbw)3 3 3 3 3 3 3 3 3 Magnesium Oxide (pbw) 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.30.3 Titanium Dioxide (pbw) 0 15 15 0 15.0 15.0 15.0 15.0 15.0 CalciumCarbonate (pbw) 200 185 185 200 185 185 185 185 185 Glass Fibers (pbw)111 111 111 111 111 111 111 111 111 PROPERTIES Shrinkage, avg. (%) 0.1480.178 0.160 0.020 0.035 0.020 0.016 0.014 0.019 Shrinkage, stddev. (%)0.012 0.026 0.014 0.011 0.017 0.008 0.014 0.031 0.014 Orange Peel, avg.49.8 50.8 42.5 26.5 29.0 26.5 25.7 — 28.0 Orange Peel, stddev. 5.4 2.74.8 4.4 1.3 3.1 3.4 — 4.1 Waviness, avg. 1590.0 1513.3 1613.3 981.7868.3 1013.8 1208.5 — 680.0 Waviness, stddev. 253.1 325.3 247.6 408.8180.0 322.1 417.8 — 211.8 Ex. 89 Ex. 90 Ex. 91 Ex. 92 COMPOSITIONPPO-MAA/styrene solution (pbw) 68.0 68.0 68.0 68.0 Trimethylolpropanetrimethacrylate 17.0 17.0 17.0 17.0 (pbw) KRATON L1203 (pbw) 5 5 5 5RICON 134 (pbw) 5 5 5 5 RICON 131MA (pbw) 5 5 5 5 t-Butylperoxybenzoate(pbw) 2 2 2 2 Zinc Stearate (pbw) 3 3 3 3 Magnesium Oxide (pbw) 0.3 0.30.3 1.0 Titanium Dioxide (pbw) 0 15.0 15.0 15.0 Calcium Carbonate (pbw)200 185 185 185 Glass Fibers (pbw) 111 111 111 111 PROPERTIES Shrinkage,avg. (%) 0.006 0.011 −0.010 0.034 Shrinkage, stddev. (%) 0.015 0.0110.012 0.014 Orange Peel, avg. 20.8 20.3 15.0 — Orange Peel, stddev. 1.23.9 1.4 — Waviness, avg. 591.7 705.0 370.0 — Waviness, stddev. 63.9175.0 205.1 —

The results of the above experiments show that the compositionscomprising the polymeric additives exhibit reduced shrinkage andimproved surface smoothness relative to compositions without thepolymeric additives.

EXAMPLES 93–97, COMPARATIVE EXAMPLES 13–14

Five compositions (Ex. 93–97) were prepared to illustrate the effect ofpolybutene compounds on uncured composition viscosity. The components ofthe compositions tested and comparative examples (C. Ex. 13–14) areprovided in Table 12. The amount of polybutene is in parts by weightbased on 100 parts by weight of the total composition. Polybutene wasmixed into a base formulation comprising 20 weight % TMPTMA crosslinkerand 80 weight % of a mix of 50 weight % of a methacrylate-cappedpoly(2,6-dimethyl-1,4-phenylene ether) having an intrinsic viscosity of0.12 dL/g (at 25° C. in chloroform) in 50 weight % styrene. Thepolybutenes used are available commercially under the trade nameINDOPOL® Polybutenes manufactured by Amoco. The polybutene numberaverage molecular weights (M_(n)) ranged from 227 to 750 atomic massunits (AMU). The components were mixed together at about 70–80° C. andthen allowed to cool about 12 hours resulting in the formation ofsol-gels.

A control example (Comparative Example 13) and a polybutadiene example(polybutadiene, Ricon 134, Mn=8000 sold by Sartomer) (ComparativeExample 14) were prepared in the same manner as Examples 93–97.Viscosities of the compositions were measured using a Brookfieldviscometer, model DVII+, equipped with a T-bar spindle and given theunits centipose (cP). The viscosity of the composition immediately aftermixing (η_(mix)) was measured at approximately 60° C. The viscosity ofthe sol-gels (η_(gel)) formed from the mixed compositions after coolingand standing overnight was measured at 25° C. The sol-gel transitiontemperature (T_(sol-gel)) was also measured for each formulation byheating sealed vials of the gels in a controlled temperature bath. Thetemperature of the bath was incrementally raised and the samples werechecked for flow upon inversion. All measurements are found in Table 13and graphically displayed in FIGS. 1 and 2.

TABLE 12 Ex. 93 Ex. 94 Ex. 95 Ex. 96 Ex. 97 C. Ex. 13 C. Ex. 14COMPOSITION PPO-MAA/styrene solution (pbw) 76 76 76 76 76 80 76Trimethylolpropane trimethacrylate (pbw) 19 19 19 19 19 20 19Polybutadiene M_(n) = 8000 (pbw) — — — — — — 5.0 Indopol L-4, M_(n) 227(pbw) 5.0 — — — — — — Indopol L-14, M_(n) 326 (pbw) — 5.0 — — — — —Indopol L-50, M_(n) 455 (pbw) — — 5.0 — — — — Indopol H-15, M_(n) 600(pbw) — — — 5.0 — — — Indopol H-40, M_(n) 750 (pbw) — — — — 5.0 — —

TABLE 13 η_(mix) at η_(gel) at T_(sol-gel) M_(n) polybutene 60° C. (cP)25° C. (cP) (° C.) Ex. 93 227 520 2.6E+07 60 Ex. 94 326 800 3.4E+07 65Ex. 95 455 1220 4.0E+07 95 Ex. 96 600 1700 5.0E+07 105 Ex. 97 750 18505.9E+07 105 C. Ex. 13 — 550 1.30E+07  55 C. Ex. 14 — 1250 1.00E+07  55

As depicted in FIG. 1 and from Table 13, the results show that theaddition of 5 pbw of a polybutene having a Mn of about 326 to about 600causes only a small increase (up to about 1300 cP) in initial viscosityat the mixing temperature (η_(mix)) as compared to the control samplewithout polybutene (Comparative Example 13). Upon cooling to 25° C. asol-gel is formed and the polybutene dramatically increases thecomposition viscosity by as much as 4.6×10⁷ cP (FIG. 1, η_(gel)). Afterformation of the sol-gel, the polybutene sol-gel examples exhibittransition temperatures that range between about 60° C. to about 105° C.depending on polybutene molecular weight (FIG. 2). The ComparativeExamples 13 and 14 exhibit lower transition temperatures (55° C.).

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing fromessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

All cited patents, patent applications, and other references areincorporated herein by reference in their entirety.

1. A curable composition, comprising: a functionalized poly(aryleneether); an alkenyl aromatic monomer; an acryloyl monomer; and apolybutene, wherein the polybutene has a number average molecular weightof about 300 to about 1000 atomic mass units, and the curablecomposition comprises a sol-gel having a sol-gel transition temperatureof greater than about 60° C.
 2. The composition of claim 1, wherein thecurable composition is a sol-gel having a sol-gel transition temperatureof greater than or equal to about 75° C.
 3. The composition of claim 1,wherein the curable composition is a sol-gel having a sol-gel transitiontemperature of greater than or equal to about 90° C.
 4. The compositionof claim 1, wherein the functionalized poly(arylene ether) is a cappedpoly(arylene ether) having the structureQ(J-K)_(y) wherein Q is the residuum of a monohydric, dihydric, orpolyhydric phenol; y is 1 to 100; J has the formula

wherein R¹–R⁴ are each independently selected from the group consistingof hydrogen, halogen, primary or secondary C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl,C₂–C₁₂ alkynyl, C₁–C₁₂ aminoalkyl, C₁–C₁₂ hydroxyalkyl, phenyl, C₁–C₁₂haloalkyl, C₁–C₁₂ hydrocarbonoxy, and C₂–C₁₂ halohydrocarbonoxy whereinat least two carbon atoms separate the halogen and oxygen atoms; m is 1to about 200; and K is a capping group selected from the groupconsisting of

wherein R⁵ is C₁–C₁₂ alkyl; R⁶–R⁸ are each independently selected fromthe group consisting of hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₆–C₁₈aryl, C₇–C₁₈ alkyl-substituted aryl, C₇–C₁₈ aryl-substituted alkyl,C₂–C₁₂ alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl, C₈–C₁₈ alkyl-substitutedaryloxycarbonyl, C₈–C₁₈ aryl-substituted alkoxycarbonyl, nitrile,formyl, carboxylate, imidate, and thiocarboxylate; R⁹–R¹³ are eachindependently selected from the group consisting of hydrogen, halogen,C₁–C₁₂ alkyl, hydroxy, and amino; and wherein Y is a divalent groupselected from the group consisting of

wherein R¹⁴ and R¹⁵ are each independently selected from the groupconsisting of hydrogen and C₁–C₁₂ alkyl.
 5. The composition of claim 4,wherein Q is the residuum of a monohydric phenol.
 6. The composition ofclaim 4, wherein the capped poly(arylene ether) comprises at least onecapping group having the structure

wherein R⁶–R⁸ are each independently selected from the group consistingof hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₆–C₁₈ aryl, C₇–C₁₈alkyl-substituted aryl, C₇–C₁₈ aryl-substituted alkyl, C₂–C₁₂alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl, C₈–C₁₈ alkyl-substitutedaryloxycarbonyl, C₈–C₁₈ aryl-substituted alkoxycarbonyl, nitrile,formyl, carboxylate, imidate, and thiocarboxylate.
 7. The composition ofclaim 1, wherein the functionalized poly(arylene ether) is aring-functionalized poly(arylene ether) comprising repeating structuralunits having the formula

wherein each L¹–L⁴ is independently hydrogen, an alkenyl group, or analkynyl group; wherein the alkenyl group is represented by

wherein L⁵–L⁷ are independently hydrogen or methyl, and a is an integerfrom 1 to 4; wherein the alkynyl group is represented by

CH₂

_(b)C≡C-L⁸ wherein L⁸ is hydrogen, methyl, or ethyl, and b is an integerfrom 1 to 4; and wherein about 0.02 mole percent to about 25 molepercent of the total L¹–L⁴ substituents in the ring-functionalizedpoly(arylene ether) are alkenyl and/or alkynyl groups.
 8. Thecomposition of claim 1, wherein the alkenyl aromatic monomer has thestructure

wherein each R¹⁶ is independently selected from the group consisting ofhydrogen, C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₂–C₁₂ alkynyl, and C₆–C₁₈ aryl;each R¹⁷ is independently selected from the group consisting of halogen,C₁–C₁₂ alkyl, C₁–C₁₂ alkoxyl, and C₆–C₁₈ aryl; p is 1 to 4; and q is 0to
 5. 9. The composition of claim 1, wherein the alkenyl aromaticmonomer comprises at least one alkenyl aromatic monomer selected fromthe group consisting of styrene, alpha-methylstyrene, 2-methylstyrene,3-methylstyrene, 4-methylstyrene, 2-t-butylstyrene, 3-t-butylstyrene,4-t-butylstyrene, 1,3-divinylbenzene, 1,4-divinylbenzene,1,3-diisopropenylbenzene, 1,4-diisopropenylbenzene, styrenes having from1 to 5 halogen substituents on the aromatic ring, and mixturescomprising at least one of the foregoing alkenyl aromatic monomers. 10.The composition of claim 1, wherein the acryloyl monomer comprises atleast one acryloyl moiety having the structure

wherein R¹⁸ and R¹⁹ are each independently selected from the groupconsisting of hydrogen and C₁–C₁₂ alkyl, and wherein R¹⁸ and R¹⁹ may bedisposed either cis or trans about the carbon-carbon double bond. 11.The composition of claim 1, wherein the acryloyl monomer comprises atleast one acryloyl moiety having the structure

wherein R²⁰–R²² are each independently selected from the groupconsisting of hydrogen, C₁–C₁₂ alkyl, C₂–C₁₂ alkenyl, C₆–C₁₈ aryl,C₇–C₁₈ alkyl-substituted aryl, C₇–C₁₈ aryl-substituted alkyl, C₂–C₁₂alkoxycarbonyl, C₇–C₁₈ aryloxycarbonyl, C₈–C₁₈ alkyl-substitutedaryloxycarbonyl, C₈–C₁₈ aryl-substituted alkoxycarbonyl, nitrile,formyl, carboxylate, imidate, and thiocarboxylate.
 12. The compositionof claim 11, wherein the acryloyl monomer comprises at least twoacryloyl moieties.
 13. The composition of claim 1, wherein the acryloylmonomer comprises at least one acryloyl monomer selected from the groupconsisting of trimethylolpropane tri(meth)acrylate, 1,6-hexanedioldi(meth)acrylate, ethylene glycol di(meth)acrylate, propylene glycoldi(meth)acrylate, cyclohexanedimethanol di(meth)acrylate, butanedioldi(meth)acrylate, diethylene glycol di(meth)acrylate, triethylene glycoldi(meth)acrylate, isobornyl (meth)acrylate, methyl (meth)acrylate,ethoxylated trimethylolpropane tri(meth)acrylate, propoxylatedtrimethylolpropane tri(meth)acrylate, and mixtures comprising at leastone of the foregoing acryloyl monomers.
 14. The composition of claim 1,comprising about 0.1 to about 30 parts by weight of polybutene, based on100 parts by weight total of the functionalized poly(arylene ether), thealkenyl aromatic monomer, the acryloyl monomer, and the polybutene. 15.The composition of claim 1, further comprising at least one curingcatalyst selected from the group consisting of benzoyl peroxide, dicumylperoxide, methyl ethyl ketone peroxide, lauryl peroxide, cyclohexanoneperoxide, t-butyl hydroperoxide, t-butyl benzene hydroperoxide, t-butylperoctoate, 2,5-dimethylhexane-2,5-dihydroperoxide,2,5-dimethyl-2,5-di(t-butylperoxy)-hex-3-yne, di-t-butylperoxide,t-butylcumyl peroxide,alpha,alpha′-bis(t-butylperoxy-m-isopropyl)benzene,2,5-dimethyl-2,5-di(t-butylperoxy)hexane, di(t-butylperoxy isophthalate,t-butylperoxybenzoate, 2,2-bis(t-butylperoxy)butane,2,2-bis(t-butylperoxy)octane, 2,5-dimethyl-2,5-di(benzoylperoxy)hexane,di(trimethylsilyl)peroxide, trimethylsilylphenyltriphenylsilyl peroxide,2,3-dimethyl-2,3-diphenylbutane,2,3-trimethylsilyloxy-2,3-diphenylbutane, and mixtures comprising atleast one of the foregoing curing catalysts.
 16. The composition ofclaim 1, further comprising a fibrous filler.
 17. The composition ofclaim 16, wherein the fibrous filler is glass fiber.
 18. The compositionof claim 16, comprising about 2.0 to about 80 weight percent of thefibrous filler, based on the total weight of the composition.
 19. Thecomposition of claim 1, further comprising a particulate filler.
 20. Thecomposition of claim 19, comprising about 5.0 to about 80 weight percentof the particulate filler, based on the total weight of the composition.21. The composition of claim 1, further comprising an additive selectedfrom the group consisting of flame retardants, mold release agents andmixtures comprising at least one of the foregoing additives.
 22. Thecurable composition of claim 1, wherein the functionalized poly(aryleneether) is present at about 10 to about 90 parts by weight; the alkenylaromatic monomer is present at about 10 to about 90 parts by weight, theacryloyl monomer is present at about 1.0 to about 50 parts by weight,and the polybutene is present at about 0.1 to about 30 parts by weightbased on 100 parts by weight total of the functionalized poly(aryleneether), the alkenyl aromatic monomer, the acryloyl monomer, and thepolybutene.
 23. The curable composition of claim 22, wherein the curablecomposition is a sol-gel having a sol-gel transition temperature ofgreater than about 60° C.
 24. The curable composition of claim 22,further comprising about 2 to about 80 weight percent glass fiber basedon the total composition.
 25. A cured composition, comprising thereaction product of the composition of claim
 1. 26. An articlecomprising the composition of claim
 25. 27. A curable composition,comprising: a functionalized poly(arylene ether); an alkenyl aromaticmonomer; an acryloyl monomer; a polybutene; and a filler, wherein thepolybutene has a number average molecular weight of about 300 to about1000 atomic mass units and the composition comprises a sol-gel having asol-gel transition temperature greater than about 60° C.